Wireline Module 1

Index
Page

1 FACILITY SAFETY 1-1

1.1 RULES AND REGULATIONS 1-1
1.1.1 Classroom House Rules 1-1
1.1.2 Workshop Or Well Site Rules 1-2
1.1.3 Course Rules 1-3
1.1.4 Fire Plan 1-4

2 ORIGINS OF OIL AND GAS 2-1

2.1 INTRODUCTION 2-1
2.2 COMMERCIAL OIL FIELDS 2-1
2.3 RESERVOIR DRIVE MECHANISMS 2-2
2.3.1 Internal Drive 2-2
2.3.2 Depletion Drive 2-2
2.3.3 External Gas Cap 2-2
2.3.4 Water Drive 2-2
2.3.5 External Drive 2-3

3 COMPLETION DESIGN 3-1

3.1 INTRODUCTION 3-1
3.2 WIRELINE RE-ENTRY GUIDE 3-1
3.3 TUBING PROTECTION JOINT 3-1
3.4 NO-GO LANDING NIPPLE 3-1
3.5 PERFORATED PUP JOINT 3-3
3.6 LANDING NIPPLE 3-3
3.7 PUP JOINT 3-3
3.8 CROSSOVER 3-3
3.9 MILLOUT EXTENSION 3-3
3.10 PACKER 3-4
3.11 POLISHED BORE RECEPTACLE (PBR) 3-4
3.12 TUBING LANDING NIPPLE 3-4
3.13 SIDE POCKET MANDREL 3-4
3.14 MID-TUBING LANDING NIPPLE 3-4
3.15 FLOW COUPLING 3-5
3.16 SAFETY VALVE WIRELINE NIPPLE 3-5
3.17 TUBING 3-5
3.18 CONTROL LINE 3-5
3.19 TUBING HANGER 3-5

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4 XMAS TREES 4.1

4.1 INTRODUCTION 4.1
4.2 VALVES 4.1
4.2.1 Lower Master Valve (LMV) 4.1
4.2.2 Upper Master Valve (UMV) 4.1
4.2.3 Flow Wing Valve (FWV) 4.1
4.2.4 Kill Wing Valve 4.3
4.2.5 Choke Valve 4.3
4.2.6 Swab Valve 4.3
4.3 XMAS TREE CAP 4.3

5 SAFETY OFFSHORE 5-1

5.1 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH) 5-1
5.1.1 Ill Health And Hazardous Substances At Work 5-1
5.1.2 COSHH Regulations 5-1
5.1.3 Hazard And Risk 5-2
5.1.4 Hazard 5-2
5.1.5 Risk 5-2
5.1.6 Complying With COSHH 5-2
5.1.7 Assessment 5-3
5.1.8 Who Carries Out The Assessment 5-3
5.1.9 Recording And Reviewing The Assessment 5-3
5.2 H2S GAS 5-3
5.2.1 H2S May Be Found 5-4
5.2.2 Precautions Against H2S Gas 5-4
5.2.3 Control 5-4
5.3 LIFTING TECHNIQUE 5-4
5.4 THE PERMIT TO WORK SYSTEM 5-9
5.4.1 Safe Working System 5-9
5.4.2 Overview Of The Permit To Work System 5-9
5.4.3 Permits To Work 5-10
5.4.4 Supplementary Certificate 5-15
5.4.5 Definition Of Personnel And Responsibilities 5-17
5.4.6 Procedure For Completing A Permit To Work Form 5-18

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6 WHAT IS WIRELINE? 6.1

6.1 INTRODUCTION 6.1
6.2 BENDING STRESSES 6.4
6.3 RE-SPOOLING 6.5
6.4 HANDLING AND STORAGE 6.5
6.5 GENERAL SAFETY PRECAUTIONS 6.6
6.6 WIRELINE TORSION TESTER 6.8
6.6.1 Objective 6.8
6.6.2 Procedure 6.8
6.6.3 Slickline Operation And Maintenance 6.9
6.6.4 Torsion Test Specimen Configuration 6.12
6.7 WIRELINE TEST ANALYSIS 6.13
6.7.1 Acceptance 6.13
6.7.2 Torsion Fracture Analysis 6.13
6.7.3 Fracture Classification 6.13
6.7.4 General Guidance Notes 6.15

7 QUICK UNIONS 7.1

7.1 INTRODUCTION 7.1
7.1.1 Wellhead Adapter (Tree Adapter) 7.5
7.1.2 Pump-In Tee 7.6
7.1.3 Wireline Blow Out Preventer (BOP) 7.7
7.2 WIRELINE BOP 7.10
7.2.1 Pressure Testing Of Wireline BOP 7.10
7.3 LUBRICATORS 7.11
7.3.1 Injection Sub 7.14
7.4 CUTTER VALVE 7.15
7.5 WORKOVER VALVE 7.15
7.6 STUFFING BOX 7.16
7.7 HYDRAULIC PACKING NUT 7.18

8 WIRELINE UNIT 8.1

8.1 HAY PULLEY AND WEIGHT INDICATOR 8.4
8.2 HAY PULLEY 8.4
8.3 WEIGHT INDICATOR 8.5
8.3.1 Introduction 8.5
8.4 MEASURING WHEEL 8.7
8.5 CAUSES FOR DEPTH DISCREPANCIES 8.8
8.5.1 Wireline Angle Correction Factors 8.9
8.6 WIRELINE CLAMP 8.12

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9 POWER PACKS 9.1

9.1 ELECTRICAL 9.1
9.2 DIESEL POWER PACKS 9.3
9.2.1 FAULT FINDING CHART 9.4

10 WELL CONTROL AND B.O.P. PUMPS 10.1

10.1 SINGLE WELL CONTROL PANEL 10.1
10.2 OPERATING PROCEDURES 10.1
10.2.1 Pre-Operational Function Checks 10.1
10.2.2 Routine Operating Procedures 10.2

11 GENERAL TOOLSTRING 11.1

11.1 PRIMARY EQUIPMENT 11.2
11.1.1 Rope Sockets 11.2
11.1.2 Wireline Stem 11.3
11.1.3 Lead Stem 11.5
11.1.4 Roller Stem 11.6
11.1.5 Jars 11.7
11.1.6 Stretch Simulators/Accelerators 11.13
11.2 TOOLSTRING ACCESSORIES 11.15
11.2.1 Quick-Lock System (Petroline) 11.15
11.2.2 Trinity Quick-Lock System 11.17
11.2.3 Knuckle Joints 11.18

12 BASIC PULLING TOOLS 12.1

12.1 FISHING NECK IDENTIFICATION / EXTERNAL / INTERNAL / REACH 12.1
12.1.1 Selection of Shear Direction 12.2
12.2 EXTERNAL BASIC PULLING TOOLS 12.4
12.2.1 Otis ‘S’ Series Pulling tools (Shear down to release) 12.4
12.2.2 Otis ‘R’ Series Pulling Tools (Jar up to release) 12.5
12.2.3 Camco ‘JD’ Series Pulling Tools (Jar down for release) 12.8
12.2.4 ‘JU’ Series Pulling Tools (Jar up to release) 12.10
12.2.5 Otis "GS" Pulling Tool 12.13
12.2.6 Otis "GR" Pulling Tool 12.18
12.2.7 Otis "GU" Adapter 12.21
12.2.8 Shear Stock Sizes/Shear Pins 12.22

13 BASIC WIRELINE TOOLS 13.1

13.1 GAUGE CUTTER 13.1
13.2 LEAD IMPRESSION BLOCK 13.2
13.3 BLIND BOX 13.3
13.4 TUBING END LOCATOR 13.4

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14 SAFETY AND AREAS OF RESPONSIBILITY 14.1

14.1 GENERAL SAFETY 14.1
14.1.1 Introduction 14.1
14.1.2 Wireline Safety (Refer to Expro Operational Guidelines) 14.1
14.2 WIRELINE OPERATIONAL GUIDELINES 14.4
14.2.1 Surface Operations 14.4
14.2.2 Equipment Location and Layout 14.4
14.2.3 Rig-Up/Rig-Down Considerations 14.6
14.2.4 Pressure Testing and Pressurising Lubricators (Refer to Expro Operational
Guidelines) 14.6
14.2.5 Pressure Testing Wireline BOPs 14.9
14.2.6 De-pressurising Lubricators 14.9

15 APPENDICES 15.1
15.1.1 Safety Shutdown System 15.1
15.1.2 Exhaust Temperature Probes 15.3
15.1.3 Coolant Temperature Probe 15.5
15.1.4 Engine Breather Flame Trap 15.6
15.1.5 Inlet System 15.7
15.1.6 D-Valve 15.8
15.1.7 Cleaning The Inlet Flametrap Element 15.12
15.1.8 Additional Safety Notes 15.12
15.1.9 Exhaust System 15.13
15.1.10 Troubleshooting - Diesel Engines 15.15

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1 FACILITY SAFETY

1.1 RULES AND REGULATIONS

1.1.1 Classroom House Rules
a) Starting time will be 08:30 and finishing time 17:30, Monday through Friday.
• Coffee Breaks - 15 minutes in the morning.
- 15 minutes in the afternoon, depending on workload.
• Lunch break will be 30 minutes or at the instructor's discretion.

b) All materials, handouts etc. will be collected and left tidy on your desk at the end of
each day.
• Empty coffee cups and rubbish must be disposed in the bins provided.

c) Due to the number of students which may be using the facility at the same time, the
canteen will become busy. We therefore request that after you have finished eating
you return to the recreation area, smoking area or elsewhere until the class begins
again. This will allow other students and staff access to the canteen.
d) A sensible dress code will be expected while working in the classroom.

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1.1.2 Workshop Or Well Site Rules
a) Lockers
Lockers will be provided for all students during the course. The locker will be your
personal responsibility and kept clean and tidy. Also keep the changing room tidy.

b) Wellsite
We must assume the work area is a pipe deck offshore and respect it the same manner.
• All equipment must be rigged up and laid out neatly.
• All oil or diesel spillage must be mopped up immediately using the oil spill
granules or cleaning fluids provided.
• After rigging down the unit, the workbench and tools must be cleaned and
returned to the appropriate storage place and left as you would expect to find it.

c) All downhole tools used will be stripped, cleaned and redressed, if necessary, ready
for the next class.
d) When outside on the Training Well you will always wear the following:
• Hard Hat
• Safety Boots
• Coveralls
• Safety Glasses
• Gloves
• Hearing Protection as required

e) Equipment operating signals

There are a number of signals that must be learnt know in order to acknowledge proper
functioning and movement of the wireline equipment. These signals will be demonstrated
to you and must be used at all times when working with the wireline unit.

f) Safety harness
As offshore, all students must wear a safety harness while working any more than 1.5
metres off the ground.
• While rigging the equipment up or down these safety harnesses will be
provided and will be used.

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1.1.3 Course Rules
1) Personnel safety is paramount. Always wear Personal Protective Equipment (PPE)
when working outside, in the workshop or wellhead areas.
2) Report all accidents or incidents to your instructor, no matter how trivial they may
seem at the time. Seek medical aid if required. If accidents are not reported,
appropriate actions cannot be implemented to prevent similar future occurrences.
3) No alcohol is to be consumed in the training centre, unless authorised for special non-
training occasions. Any student found under the influence of alcohol will be
immediately expelled from the class and reported to his immediate line manager.
4) Full effort by students is expected on all courses.
5) Random alcohol and/or substance abuse test may be carried out during the term of
the course.
6) PPE and dirty clothes/shoes shall not be worn inside the building i.e. classroom,
recreation area, office, etc.
7) As you are not the only students using the facility, please show respect for others.
No foul language and no obscene materials are allowed.
8) Good housekeeping is required everywhere, including the locker facilities and toilets.
9) You are expected to be in class by 08.30 am each day and you will be allowed coffee
and lunch breaks at the set times. Your course instructor will advise you of these
times.
10) The course register must be filled in each day. The register keeper should deliver it
to the training secretary by 08.45 am.
11) Tristar operate a no smoking policy within the training centre, however a designated
smoking area is provided for delegates.

SIGNED DATE

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1.1.4 Fire Plan

Figure 1.1 - Emergency Fire Plan

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2 ORIGINS OF OIL AND GAS

2.1 INTRODUCTION
Petroleum (derived from the Greek ‘Petra’ for rock and the Latin ‘Oleum’ for oil) is
obtained from the fluids contained in underground reservoirs.
The hydrocarbons contained in these fluids have had their origins in the residues of plant
and animal life, which were washed into sedimentary basins and buried through time.
Subjected to abnormal temperature and pressure gradients, the fats and proteins in these
residues are probably decomposed anaerobically (without oxygen) in the source rock to
form the hydrocarbons known generically as gas, condensate, or black oil.
The formation of these hydrocarbons is invariably accompanied by volume changes with
high increases in local pressure. These pressure increases probably initiate microfractures
in the sedimentary rock, thereby allowing the hydrocarbons to migrate along potential
gradients until they surfaced, or were caught in traps.
Most traps are structural anticlinal or fault traps which are common to the majority of
sedimentary basins. Three dimensional containment is established by an impermeable seal
above, around the sides, and by the buoyancy of the hydrocarbons on underlying water.
This section contains a discussion of the Organic Theory of Petroleum which is the widely
accepted version by the scientific world, with a brief overview of geological structures
which form petroleum reservoirs.

2.2 COMMERCIAL OIL FIELDS

In order for an oil and gas field to exist, four basic conditions must have been met:
• A source from which hydrocarbons originated, with suitable environmental
conditions that changed the source material into petroleum
• A porous rock bed laid down, through which the petroleum could migrate to its
reservoir rock.
• A suitably shaped trap formed under which the petroleum accumulated
• An impervious cap or seal rock overlaid causing the trap.

To ensure that a field is commercially viable, the reservoir rock must in addition exhibit
three further essential characteristics:
• Continuity between pore spaces or permeability. There must be some degree of
continuity between void spaces so that reservoir fluids can flow through long
distances under very small pressure gradients
• Hydrocarbons must be of low enough molecular weight and, therefore,
viscosity to allow flow to occur.
• Must have an organic content at least greater than 1% (the organic content of
typical North Sea hydrocarbon-bearing rock exceeds 7%).

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2.3 RESERVOIR DRIVE MECHANISMS
Ideally in an offshore oil field, the hydrocarbons are recovered from the reservoir pore
spaces by exploiting a drive mechanism, precluding the need for artificial methods. Drive
mechanisms have two classifications:
• Internal drive using the internal energy of the reservoir configuration
• External drive which involves the invasion of the pore spaces by a replacement
fluid.

2.3.1 Internal Drive

This is known as primary recovery, which includes three drive mechanisms:
• Depletion or internal gas drive.
• External gas cap drive.
• Water drive.

2.3.2 Depletion Drive

The compressibility of oil and water is relatively small. As soon as production commences,
it is accompanied by a rapid drop of pressure in the producing zone which soon reaches the
bubble point of entrained gas. See Figure 2.1 Initially, this gas is dispersed, but it rapidly
expands and assists in dispelling the oil. Eventually, however, the gas will start to form a
gas front, which, having more mobility than the oil, and increases the production gas/oil
ratios. This depletion or internal gas drive is characterised by a rapid decline in reservoir
pressure and by the recovery of only a small percentage of the oil in situation of 5 to 20 %
maximum.

2.3.3 External Gas Cap

Where the oil has a gas cap, the gas cap pressure together with the pressure of gas in
solution tends to maintain pressure in the reservoir much longer than depletion drive. See
Figure 2.1. Therefore gas cap reservoirs have higher recovery rates of (20 to 40%).

2.3.4 Water Drive

Water drive is characterised by large local deposits of water which expand as pressure is
reduced in the reservoir see Figure 2.1. Eventually, recovery will decrease due to the
greater mobility of the water front which eventually breaks through to the wellbore with
increasing water/oil ratios. Nonetheless, water drive is the most efficient of the drive
mechanisms and can produce recovery rates as high as 60 %.
All three drive mechanisms may be present to varying degrees at the same time although
one will be predominant.

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2.3.5 External Drive
If a fluid is injected into a well so that the volumetric rate of fluid replacement is equal to
the volumetric rate of fluid extraction, then the average reservoir pressure will tend to
remain constant. Injection stimulates secondary recovery.
Depending on the type and configuration of the reservoir, pressure can be maintained
therefore by:
• Gas injection
• Water injection
• Miscible and immiscible fluid injection.

In general, gas is injected into the crest, and water injection into the base or periphery of
the reservoir. Particular consideration must be given to the quality of the injection fluids,
compatible with existing reservoir fluids, filtered to prevent formation plugging, viscose
which should be significantly higher than formation water, variations in reservoir
permeability, and injection rate. If the injection rate is excessive, the water front may
advance unevenly, thus giving rise to early water breakthrough, or to unstable coning round
the borehole.

Figure 2.1 – Reservoir Drive Mechanisms

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3 COMPLETION DESIGN

3.1 INTRODUCTION
The example completion selected (refer to Figure 3.1), is a typical modern example of a
simple and versatile design.
The equipment used in this completion is that commonly used in North Sea type
completions, with their specific applications and uses outlined in the sub-sections below.
Starting with item 25, on the completion schematic (which is the first item to be run in the
hole), there follows a brief description of the use and position of each item of equipment in
the string.

3.2 WIRELINE RE-ENTRY GUIDE

(Refer to Item 25 on the diagram.)
This guide, sometimes abbreviated to WEG, is generally available in two forms.
a) Bell Guide
This guide has a 45° lead-in taper to allow easy re-entry of wireline tools into the tubing
strings. This guide is used in a completion where the end of the tubing does not need to
enter the top of liner hanger or packer tops.

b) Mule Shoe Re-Entry

This guide is essentially the same as a bell guide, but modified by having a large 45° angle
cut across from the outside of the guide. The 45° shoulder when orientated by turning the
tubing enables the guide to enter liner tops.

3.3 TUBING PROTECTION JOINT

(Item 24)
This is a single joint of tubing, included for the particular purpose of protecting
pressure/temperature gauges that may be suspended from the landing nipple immediately
above.

3.4 NO-GO LANDING NIPPLE

(Item 23)
This nipple is used exclusively for the installation of wireline set gauge hangers.

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Figure 3.1 - Typical Completion Schematic

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3.5 PERFORATED PUP JOINT
(Item 22)
In wells having large flow volumes, a restriction in the tubing such as a gauge hanger, will
cause false pressure recordings. Vibration due to flow turbulence may also cause extensive
damage to the gauges, therefore a perforated pup joint (approx. 10 ft long) is installed
above the gauge hanger nipple. This allows flow to pass unrestricted around the gauges and
hanger, providing accurate pressure/temperature recordings within the limits of the gauge..
The total area of the perforations must be greater than the ID of the pup joint (generally 3-4
times the area).

3.6 LANDING NIPPLE

(Item 21)
This nipple is the primary plugging point below the packer and is used during the initial
completion stage as a receptacle for a ‘test tool’. A test tool is a plug, which will only hold
pressure from above and does not lock into the nipple. It should hold sufficient pressure to
enable the setting of the hydraulic packer, and then testing the tubing.
After its initial use as described above, the nipple is used for well plugging by installing the
appropriate type plug (e.g. when tubing above the packer has to be pulled leaving the
packer in the hole).

3.7 PUP JOINT

(Item 20)
Used for spacing out tubing or as a handling joint when completion equipment is made up
into sub-assemblies for ease of handling and quick completion installation.

3.8 CROSSOVER
(Item 19)
A crossover is a connector which fits between two different sizes or types of threaded
connections. For instance between 4 ½” to 5 ½” or 3 ½” to 4 ½” tubing, etc.

3.9 MILLOUT EXTENSION

(Item 18)
This is generally a pup joint with a slightly larger ID than the packer bore and provides a
shoulder onto which a packer-plucker can latch during packing/milling operations. This
enables the packer and tail-pipe assembly to be retrieved during the same run as the milling
operation.

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3.10 PACKER
(Item 17)
The packer in the example is a hydraulic type set permanent packer, which is installed on
the production string. It isolates the producing zone from the tubing/casing annulus. This
protects the production casing from well pressure and corrosive fluids maintaining its
integrity over the life of the well.

3.11 POLISHED BORE RECEPTACLE (PBR)

(Item 16)
The seal receptacle is attached to the top of the packer. The seal assembly, which mates
with the PBR, is attached to the bottom of the tubing string.
The function of the PBR is to allow travel upwards and downwards within the PBR to cater
for tubing movement due to expansion or contraction of the tubing caused by flowing
conditions or well operations.
Sometimes the seals are attached to the PBR with shear-pins or shear-ring in order that the
completion can be installed in one trip. The shear pins or shear ring can then be
hydraulically or mechanically sheared to allow travel, after the packer has been set.

3.12 TUBING LANDING NIPPLE

(Item 15)
This nipple is used for testing the tubing above the packer. In conjunction with item 21, it
can be used to find if tubing leaks are present above or below the packer.

3.13 SIDE POCKET MANDREL

(With Shear Relief Valve)
(Item 14)
This is an alternative circulating device to a conventional sliding side door (SSD), which
can incorporate an annulus pressure actuated circulating valve. The valve is operated by
applying pressure to the annulus which is the annular space between the tubing OD and the
production casing ID.

3.14 MID-TUBING LANDING NIPPLE

(Item 10)
This landing nipple would is installed at approx. 3,500 ft and would normally be used for
plugging the well if a neighbouring well is being drilled in the immediate vicinity and is to
be ‘kicked off’ or deviated. The kick-off point for deviated wells in the North Sea is
generally around 2000 ft. If, in the unlikely event, the drill-bit should penetrate the well,
the reservoir pressure would be isolated from reaching the drill string by the plug in the
nipple.

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3.15 FLOW COUPLING
(Item 9)
When flowing a high rate well, the fluid will move at extremely high speed. When meeting
a restriction, such as a nipple profile, excessive turbulence will develop immediately above
the nipple causing excessive erosion. To cater for this excessive erosion, a six foot joint of
heavy walled tubing would be installed above (and sometimes below) the nipple. Although
the same amount of erosion will be experienced, the added wall thickness of the flow
coupling will leave sufficient material intact to prevent any leakage during the life of the
well.

3.16 SAFETY VALVE WIRELINE NIPPLE

(Item 5)
This nipple is designed to accommodate a wireline retrievable safety valve, remotely
operated from the surface by a hydraulic control line,
• (Item 4) - See Item 9
• (Item 3) - See Item 20

The other common type of safety valve used is the tubing retrievable type safety valve.
This valve is installed as a component of the tubing string and also requires a control line
for operation from surface.

3.17 TUBING
(Item 2)
Tubing is the flow conduit for the produced fluids. It is manufactured in lengths, termed
joints, of approximately 30 to 35 feet long.
The tubing connects all of the other completion components together from the re-entry
guide to surface.

3.18 CONTROL LINE

(Item 1)
This is normally a 1/4 inch OD Monel or stainless steel tubing, connected between the
safety valve nipple (or tubing retrievable valve) and the tubing hanger. The control line is
held against the tubing by stainless steel banding or metal clamps. It is the conduit used for
the supply of hydraulic pressure from the surface control panel to the safety valve.

3.19 TUBING HANGER

The tubing hanger (not shown) supports the weight of the completion string in the wellhead
and also seals between the tubing/Xmas tree bore and the annulus.

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4 XMAS TREES

4.1 INTRODUCTION
A Xmas tree is an assembly of valves and fittings used to control the flow of wellfluids at
surface and to provide access to the production tubing. The Xmas tree is essentially a
manifold of valves which is installed as a unit on top of a tubing head upper flange, or
adapter flange, of a wellhead; Figure 4.1.

4.2 VALVES
Typically, from bottom to top, a Xmas tree will contain the following valves:

4.2.1 Lower Master Valve (LMV)

• Application:- Utilised in all Xmas trees to close in the well
• Operation:- Manual.

The master valve, as its name implies, is the most important valve on the Xmas tree. When
closed this valve contains well pressure and should only be used ofr safety and isolation
purposes and never be used as a working valve.
In moderate to high pressure wells, Xmas trees are often provided with two master valves,
the upper of which is furnished with a valve actuator system for automatic or remote
controlled operation (surface safety valve). This is often a regulatory requirement in sour or
high pressure wells.

4.2.2 Upper Master Valve (UMV)

• Application:- Utilised on moderate to high pressure wells as an emergency
shut in system. The valve is sometimes capable of cutting 7/32 inch braided
wireline.
• Operation:- Valve actuated pneumatically or hydraulically.

The UMV is a surface safety valve and is normally connected to the emergency shutdown
(ESD) system.

4.2.3 Flow Wing Valve (FWV)

• Application:- To permit the passage of well fluids to the choke valve.
• Operation:- Manual or automatic (pneumatic/hydraulic) depending on
whether the surface safety system includes the production wing.

On moderate to high pressure wells, two production wing valves are installed, one manual
and the other equipped with a valve actuator.

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Figure 4.1 - Xmas Tree Valve System

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4.2.4 Kill Wing Valve
• Application:- To permit entry of kill fluid into the completion string and also
for pressure equalisation across tree valves, e.g. during wireline operations or
prior to the removal/opening of a sub-surface safety valve.
• Operation:- Manual.

Kill fluid is a high density fluid designed to overcome and control formation pressures in
the event of an emergency or, if for any reason it is necessary to remove the Xmas tree
from the wellhead.

4.2.5 Choke Valve

• Application:- Utilised to restrict, control or regulate the flow of
hydrocarbons to the production facilities.
• Operation:- Manual or automatic.

This valve may be of the fixed or adjustable type. It is the only valve in the Xmas tree that
is used to control flow.

NOTE: All other valves used on Xmas trees are invariably the gate valve type
providing full bore access to the well i.e. the valve must be operated in the
fully open/fully closed positions.

4.2.6 Swab Valve

• Application:- This permits vertical entry to the well for well intervention
such as wireline, coiled tubing and snubbing methods.
• Operation:- Manual.

The swab valve is the uppermost valve on the Xmas Tree. In combination with a wireline
lubricator, refer to Figure 4.2, it allows the running of wireline tools, instruments, and other
equipment into the well, under pressure.

4.3 XMAS TREE CAP

• Application:- Provides the appropriate connection for the wireline lubricator.
• Installation:- Directly above the swab valve.

The Xmas tree cap normally incorporates a quick union-type connection, which should be
capable of supporting the lubricator for wireline work. The ID should permit the running of
wireline equipment compatible with the tubing size.

CAUTION: Always ensure that swab valve is closed and that pressure is fully bled
off before attempting to remove the Xmas tree cap.

NOTE: The Xmas tree should have a rated working pressure greater than the
closed in tubing head pressure of a well.

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All Xmas tree valves and components must, at minimum, meet API Spec. 6A -
Specifications for wellhead equipment, which specifies all essential dimensions,
pressure/temperature ratings, material properties and composition, and testing procedures.
The throughbore of a Xmas tree is specified by API and is generally 1/16 inch larger than
the tubing ID.

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Figure 4.2 - Wireline Surface Equipment

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5 SAFETY OFFSHORE

5.1 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

(COSHH)
5.1.1 Ill Health And Hazardous Substances At Work
Every year exposure to hazardous substances at work affects the health of many thousands
of people. The results can be discomfort, pain, time off work and, all too often, premature
retirement and early death. Some common examples are:
• Long term disability from lung disease following years of work in industry
conditions.
• Injuries to hands and eyes from contact with corrosive liquids.
• Death or injury from exposure to toxic fumes - damage can be caused by the
fumes and by falling after losing consciousness.

Apart from the pain and suffering, there is also a high economic price to be paid for all this
occupation ill health. The workers and their families lose earnings. Employers lose money
from reduced productivity and lost production. Accidents cause disruption. Prosecutions
and civil actions can be very expensive. The nation as a whole has to pay for the sickness
benefit and National Health Service care involved.

5.1.2 COSHH Regulations

The COSHH Regulations provide a framework to help protect personnel in the workplace
against health risks from hazardous substances. Some examples of such substances were
given above. There are many others. They may be used directly in the work, like paints,
cleaning materials and chemical reagents, or they may arise from the work, like dusts,
fumes and waste products. Others occur naturally, such as fungal spores in agriculture.
COSHH lays down a sensible step-by-step approach to the necessary precautions. It sets
out essential measures that employers, and sometimes employees have to take. Failure to
comply with COSHH may expose people to risk and is an offence subject to penalties
under the Health and Safety at Work etc. Act 1974 (HSWA), but it is better to look at
COSHH as a useful tool of good management. In a recent HSE survey, employers who put
real effort into making COSHH work reported many benefits from doing so. For example,
they had saved money from tighter control over the use and storage of materials, through
staff training on COSHH and led to better understanding of health and safety, improved
morale and industrial relations.
All employers have to consider how COSHH affects their business. Many are able to
comply with the regulations with little trouble, while others whose work involves greater
risks have more to comply with.

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5.1.3 Hazard And Risk
The words hazard and risk are used often in this section. They have special meanings in
the regulations and guidance about substances at work. The difference between them is
important for a correct understanding of COSHH.

5.1.4 Hazard
The hazard presented by a substance is its potential to cause harm. It may cause coughing,
damage to internal organs or even cause death. Some substances can cause harm in several
ways, by breathing, swallowing or absorption through the skin.

5.1.5 Risk
The risk from a substance is the likelihood that it will cause harm during use. This depends
on:
• The hazard presented by the substance
• How it is used
• Control of exposure
• Quantity exposed to
• Length of exposure
• Personal vulnerability

There can be a substantial risk even from a substance that is not particularly hazardous, if
exposure is excessive. With proper precautions, however, the risk of being harmed by even
the most hazardous of substances can be very small.

5.1.6 Complying With COSHH

Complying with COSHH involves:
• Assessing the risks to health arising from your work.
• Deciding what precautions are needed. Work must not be carried out, which
may expose employees to hazardous substances unless both the risks and
necessary precautions have been assessed, it will be unlikely that the correct
precautions have been taken.
• Preventing or controlling the risks. The advice in this leaflet, and in the other
guidance it refers to, will help you get the assessment right, but remember that
even a perfect assessment achieves nothing unless its conclusions are put into
practice.
• Ensuring that control measures are used and maintained properly, and that any
safety procedures that have been laid down are followed.
• Monitoring the exposure of workers to hazardous substances and carrying out
appropriate health surveillance, where necessary.
• Informing, instructing and training employees about the risks and the
precautions required.

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5.1.7 Assessment
Assessment means identifying the hazards, weighing up the risks and deciding what further
action is required.
Only by such a systematic approach can it be ensured the protection of the health of
personnel who may be harmed by work activities. Piecemeal efforts are likely to be costly
and waste effort without achieving the correct results.

5.1.8 Who Carries Out The Assessment

The responsibility for the assessment rests with safety management even when others do
some or even most of the work of preparing the assessment. Whoever carries out the
assessment will need to:
• Have access to the COSHH Regulations and appropriate Approved Codes of
Practice
• Understand the requirements of those Regulations and Codes of Practice
• Have the ability and authority to get all the necessary information and to make
correct decisions about the risk and the precautions needed

If it has been concluded that there is no likelihood of risk to health, or any risk is
insignificant, the assessment is complete and no further action is needed (until review of
the assessment). If it is concluded that there are risks to health, it has to be decided what
else is needed to comply fully with the regulations.

5.1.9 Recording And Reviewing The Assessment

Unless assessment is so simple that it can easily be recalled and the conclusions explained
at any time, it should be put it in writing. Sufficient information should be included to
show how decisions about risks and precautions were arrived at and to make it clear to your
employees and others what role they have to play in the precautions.
The assessment should be reviewed regularly, at intervals of no less than 5 years duration,
whenever there is reason to believe that it is no longer valid or where there has been a
significant change in the work. It should be stated in the assessment when the next review
is intended.

5.2 H2S GAS

Properties and dangers of H2S gas
• H2S is a highly toxic (as dangerous as cyanide), flammable, colourless gas
heavier than air with the odour of rotten eggs.
• Even very low concentrations impairs the sense of smell, quickly causes
unconsciousness and kills.
• Be aware of the hazards and the proper precautions to avoid its effects.
• H2S concentrations greater than 10 parts per million are dangerous.
• H2S dangerously corrodes equipment not designed for H2S (sour) service.

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5.2.1 H2S May Be Found
• At any well site.
• In the yard, when breaking down equipment even if the equipment has come
from sweet field due to the effects of sulphate reducing bacteria.
• In laboratories.

5.2.2 Precautions Against H2S Gas

In the absence of any other information, always assume H2S is likely to be present. In areas
where there is a risk of H2S being present, either portable or fixed H2S detection equipment
must be used.
In well test operations a check for H2S will be carried out and reported as soon as reservoir
fluids reach surface. Regular subsequent checks will be carried out and reported.
Should the presence of H2S be established, supervisors must be informed so that action can
be taken to control the risk.
Persons in areas of risk must withdraw to a safe area, generally upwind in an elevated
position.
In established H2S areas, breathing apparatus and resuscitators must be available.
Personnel must familiarise themselves with the locally available breathing apparatus and
resuscitators.
PPM %
1 .0001 Can Smell.
10 .001 Allowable exposure – 8 Hours.
Danger Level
100 .01 Kills smell in 3-15 mins – burns
eyes and throat.
500 .05 Loses sense of reasoning and
balance. Respiratory disturbances
in 2-15 minutes.
700 .07 Becomes unconscious quickly.
1000 .1 Unconscious at once. Permanent
brain damage may result.
Table 5.1 – Toxicity Table

5.2.3 Control
As with other hazardous substances, safe working with H2S is controlled by the Control of
Substances Hazardous to Health (COSHH) Regulations. Company Health and Safety
System N0. 802 - Hydrogen Sulphide, details the procedures that have to be followed to
control exposure to H2S.

5.3 LIFTING TECHNIQUE

AVOID UN-NECESSARY INJURY, GET INTO THE KINETIC LIFTING HABIT.
Here are some important points, using a basic lifting operation as an example.

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a) Stop and think
Plan the lift. Where is the load to be placed?
Use appropriate aids if possible. Do you need
help with the load? Remove obstructions such
as discarded wrapping materials. For a long
lift, such as floor to shoulder height, consider
resting the load mid-way on a table or bench in
order to change grip.

b) Position the feet

Feet apart, giving balanced and stable base for
lifting (tight skirts and unsuitable footwear
make this difficult). Leading leg as far
forward as is comfortable.

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c) Adopt a good posture
When lifting from a low level, bend the knees.
But do not kneel or overflex the knees. Keep
the back straight (tucking in the chin helps).
Lean forward a little over the load if necessary
to get a good grip. Keep the shoulders level
and facing the same direction as the hips.

d) Get a firm grip

Try to keep the arms within the boundary
formed by the legs. The best position and type
of grip depends on the circumstances and
individual preference; but it must be secure. A
hook grip is less tiring than keeping the fingers
straight. If you need to vary the grip as the lift
proceeds, do it is smoothly as possible.

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e) Keep close to the load
Keep the load close to the trunk for as long as possible. Keep the heaviest side of the load
next to the trunk. If a close approach to the load is not possible, slide it towards you before
trying to lift.

f) Don’t jerk
Lift smoothly, keeping control of the load.

g) Move the feet

Don’t twist the trunk when turning to the side.

h) Put down, then adjust

If precise positioning of the load is necessary, put it down first, then slide into the desired
position.

i) Individual capability
For the working population the guideline weights will give reasonable protection to nearly
all men and between one-half and two-thirds of women. To provide similar protection to
nearly all working women, reduce the guideline weights by about a third.
Any operation involving more than twice the guideline weights should be rigorously
assessed - even for very fit, well-trained individuals working under favourable conditions.

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CAUTION: The guidelines are not precise weights. Use them with caution. If in
doubt, make a more detailed assessment.

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5.4 THE PERMIT TO WORK SYSTEM
5.4.1 Safe Working System
The purpose of the Permit To Work system (PTW) is to achieve a safe working
environment by providing management control over the various activities which may have
hazardous interactions. The system has four key features:
• It limits the potentially harmful effects of the actions of the person doing the
work, by specifying safety precautions and setting limits to the duration and
extent of the work
• It allows those responsible for overall Installation safety to be aware of the
various hazardous activities and to take a systematic overview which identifies
interactions and allows priorities to be set for conflicting work tasks
• It encourages formal and careful attention to safe systems of working, by
requiring the signature of specified individuals who must confirm that all
hazards have been identified and effective precautions taken
• It encourages those responsible for overall site safety to plan the carrying out of
tasks so that minimal inconvenience and interference is caused to other tasks or
production.

The PTW system requires the involvement of competent and responsible persons as well as
the application of particular safety measures in a controlled sequence. The PTW system
ensures that responsibility and accountability for safe working practices is passed in a
logical sequence to those responsible for the work being carried out at any given time, and
ensures that specified effective safeguards are provided.
The Tristar PTW system in operation at the training centre, has been formulated from
various offshore PTW systems to cover the activities carried out at Tristar’s unique training
facility.

5.4.2 Overview Of The Permit To Work System

The PTW system requires the allocating of a task to one of the following categories:
• Hot Work (Naked Flame)
• Hot Work (Spark Potential)
• Cold Work (Well Intervention)
• Cold Work (General Operation)
• No Permit Required.

Supplementary certificates may be required to augment the PTW when specialist activities
are performed in conjunction with a task. While separate from the PTW, they are clearly
cross-referenced on each document.
• Confirmation of isolation
• Entry

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5.4.3 Permits To Work
Hot Work (Naked Flame) Permit
a) Activities Covered
• A Hot Work (Naked Flame) Permit is required if the task involves the use of a
flame or other source of ignition. For example:
• Electrical welding
• Flame cutting
• Electrical induction pre-heating/stress relieving
• Use of heat shrink blowers
• Grinding.

b) Colour
The Hot Work (Naked Flame) Permit is red in colour.

c) Period of Validity
The Hot Work (Naked Flame) Permit is valid for a continuous period of up to 24 hours.
Revalidation is required every 12 hours or at a shift change.

d) Signatories
The Hot Work (Naked Flame) Permit must be approved by the Permit Officer or his
appointed deputy.

e) Copies
There are two copies of each Hot Work (Naked Flame) Permit. They are distributed as
follows:
• Original Performing Authority, for display at worksite
• First Copy Permit office.

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Hot Work (Spark Potential) Permit
a) Activities Covered
A Hot Work (Spark Potential) Permit is required if the task may produce or expose a
possible source of ignition. For example:
• Use of non-certified electrical/electronic equipment (megger, avometer, battery
drills, power tools, etc.)
• Opening live junction boxes
• Use of air or hydraulic powered metal cutting, chipping or caulking tools
• Use of electrical soldering irons
• Use of explosives and perforating guns
• Use of powered steel wire brushes
• Dry grit/shot blasting
• Use of battery powered camera with/without flash
• Needle gunning.

b) Colour
The Hot Work (Spark Potential) Permit is green in colour.

c) Period of Validity
The Hot Work (Spark Potential) Permit is valid for a continuous period of up to 72 hours.
Revalidation is required every 12 hours or at a shift change.

d) Signatories
The Hot Work (Spark Potential) Permit must be approved by the Permit Officer or his
appointed deputy..

e) Copies
There are two copies of each Hot Work (Spark Potential) Permit. They are distributed as
follows:
• Original Performing Authority, for display at worksite
• First Copy Permit office.

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Cold Work (Well Intervention) Permit
a) Activities Covered
A Cold Work (Well Intervention) Permit is required for a task which may not involve hot
work but still has a high risk potential. For example:
• Well servicing/wireline/coiled tubing/ logging operations.

b) Colour
The Cold Work (Well Intervention) Permit is yellow in colour.

c) Period of Validity
The Cold Work (Well Intervention) Permit is valid for continuous period of up to 24 hours.
Revalidation is required every 12 hours or at a shift change.

d) Signatories
The Cold Work (Well Intervention) Permit must be approved by the Permit Officer or his
appointed deputy.

e) Copies
There are two copies of each Cold Work (Well Intervention) Permit. They are distributed
as follows:
• Original Performing Authority, for display at worksite
• First Copy Permit Office.

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Cold Work (General Operation) Permit
a) Activities Covered
A Cold Work (General Operation) Permit is required for work which does not fall into the
preceding categories of Permit, yet still requires to be covered by a Permit.
For example:
• Brush painting operations
• General maintenance
• Erection and dismantling of scaffolds
• Work on isolated electrical equipment
• Installation of instrumentation pipework, cables and termination’s (no live tie-
ins)
• Wet shot/grit blasting
• Any work affecting the integrity or availability of safety or emergency systems
e.g., fire pumps, fire mains, shutdown systems, fire and gas detection
• Any repair, construction or overhaul work on communication systems or
equipment
• Persons(s) being in exposed locations e.g., outboard of handrails, underneath
the Installation, access to flare or derrick, or where persons may fall 2 metres or
more
• Pressure testing of plant and equipment
• Any work inside enclosed or confined spaces including tanks, vessels or non-
operational, non-ventilated areas where hazardous concentrations of toxic or
flammable gases, fumes or vapours might arise or where the oxygen content of
the air could be reduced to below 20% by volume or an excess of oxygen may
be present
• Work involving use of certified personnel work baskets
• Removal of handrails, gratings, ladders, etc.
• Chemical cleaning
• Handling of hazardous substances e.g., radioactive sources, toxic/corrosive
chemicals, asbestos, etc.
• High pressure water jetting
• Spraying of paint
• Heavy lifts, e.g. over wellheads
• Specialised rigging operations
• Any out of the ordinary activity.

b) Colour
The Cold Work (General Operation) Permit is blue in colour.

c) Period of Validity
The Cold Work (General Operation) Permit is valid for a continuous period of up to 72
hours. Revalidation is required every 12 hours or at a shift change.

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d) Signatories
The Cold Work (General Operation) Permit must be signed by the Permit Officer or his
appointed deputy.

e) Copies
There are two copies of each Cold Work (General Operation) Permit. They are distributed
as follows:
• Original Performing Authority, for display at worksite
• First Copy Permit office.

No Permit Required
a) Activities Covered
Under certain circumstances the Permit Officer may allow work to be carried out in his
area of control without the issue of a Permit. The discretion to use this facility lies entirely
with the Permit Officer. The decision must be taken only after deliberate consideration of
the circumstances.
The Permit Officer may give a verbal instruction or use a Maintenance Request form to
allow work to be carried out by suitably competent persons.
The work must not be hazardous to either the person who carries it out or to anyone else,
and the Permit Officer must be satisfied that all reasonably practicable steps have been
taken to ensure the safety of those involved, and anyone else that the work might affect.
Activities covered may include:
• Routine materials handling
• Routine work in offices.
• General cold work inside workshops
• Visual inspection of areas (not including confined spaces)
• Operating or demonstrating portable fire-fighting equipment or life saving
appliances during drills or training.

b) Workshop Operations
At his discretion the Permit Officer may issue, in the form of a memorandum, standing
orders to cover operations in workshops. Such orders can be valid only for designated
workshops and the authorised use of permanent facilities provided in the workshops. The
order should be prominently displayed in the workshops to which it refers. The
memorandum should include specific precautions and conditions to be observed.

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5.4.4 Supplementary Certificate
Isolation Confirmation Certificate

a) Activities Covered
Before a Permit to Work can be issued for a task it may be necessary for the equipment or
plant to be worked on to be isolated. The Isolation Confirmation Certificate (ICC)
combines on one document a record of all the isolations required for a task to proceed in
safety. The equipment may require isolation from:
• Sources of electricity
• Process fluids and pressure
• Mechanical drive
• Control systems.

The ICC ensures that the isolations are applied and documented in a thorough, systematic
manner.

b) Period of Validity
The ICC is raised before the Permit to Work is issued, and it remains in force at least until
the Permit to Work is cancelled. The ICC will only be cancelled upon the cancellation
declaration being signed by the Area Authority.

c) Signatories
The ICC must be signed by the Permit Officer or his deputy and each of the involved
Isolating Authorities. The Permit Officer signs for isolations to be applied or removed and
to certify that the plant is available for return to normal operations.
The Isolating Authorities sign for each isolation they apply and remove.

d) Copies
There are two copies of each ICC. One copy is retained by the issuing Isolating Authority,
the second copy is given to the Permit Office.

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Entry Certificate
a) Activities Covered
An Entry Certificate must be issued when it is necessary for personnel to enter vessels,
tanks, sumps, structural members and enclosed void spaces. Adequate safety precautions
must be taken to prevent anyone who enters these confined spaces from suffering harm or
injury.
The purpose of the Entry Certificate is to certify the atmospheric conditions inside the
confined space and stipulate the level or precautions while work is being carried out. The
Entry Certificate does not permit any work to be carried out. The appropriate Permit to
Work must be raised before any task can be undertaken.
The Entry Certificate only allows visual inspection by the Authorised Gas Tester Level 1 to
be done within the space.

b) Period of Validity
The Entry Certificate is valid for an indefinite period subject to gas retest which will be
carried out at a maximum interval of 12 hours. The Permit Officer or Authorised Gas
Tester may stipulate a more frequent retest if conditions dictate.

c) Signatories
The Entry Certificate must be signed by the Permit Officer.

d) Copies
There are two copies of each Entry Certificate. They are distributed as follows:
• Original Performing Authority, for display at worksite
• First Copy Permit office.

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5.4.5 Definition Of Personnel And Responsibilities
Everyone involved on a site or Installation, including owners, employers, contractors and
workers, may have responsibilities under Permit to Work procedures. It is important that
each individual knows what his own responsibilities and duties are and carries them out
properly.
Paragraph 10 Oil Industry Advisory Committee 'A Guide to Principles and
Operations of Permit to Work Procedures'.

a) Permit Officer (PO)

The Permit Officer is responsible for ensuring that written procedures and systems for
Permits to Work are in place. He is responsible for ensuring the competence of relevant
personnel to carry out the functions of the Permit to Work System.
The Permit Officer must approve all Hot Work (Naked Flame), Hot Work (Spark
Potential), Cold Work (Well Intervention) and Entry Certificates.
The Permit Officer may delegate the signing of Cold Work (General Operation) Permits.

b) Performing Authority
The Performing Authority is the senior person actually in charge of the task on a
continuous basis who is present on the site during the work.
The Performing Authority is responsible for and signs the Permit to acknowledge that both
he/she and his/her men will:
• Comply with the conditions specified on the Permit
• Use the protective equipment specified on the Permit.

The Performing Authority signs the Permit at the end of the task to certify:
• The status of the task specified on the Permit
• That all his workforce has been withdrawn from the worksite
• That the worksite has been left safe and clean.

c) Isolating Authority
An Isolating Authority is appointed by the Permit Officer and is responsible for the
application and removal of isolations under an ICC. The Isolating Authority carries out his
duties under the instructions of the Permit Officer. His expertise in his particular discipline
will enable him to advise the Permit Officer as to the isolations required for an ICC or
Sanction to Test. His discipline can be:
• Mechanical
• Electrical
• Process
• Control.

d) Permit Clerk (PC)

The Permit Clerk (PC) is appointed by the Permit Officer. He/she is responsible for
maintaining an up to date register of all active Permits and Certificates.

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5.4.6 Procedure For Completing A Permit To Work Form
The detailed procedures involved in completing the various sections of the Permit to Work
forms are set out in the following subsections. The sequence of compiling a Permit to Work
form is summarised below.

Section Action By Action to be Taken

Number
1 PERFORMING Ensures that Section 1 is completed giving sufficient
AUTHORITY information for subsequent personnel to assess the
task. Dates the anticipated time frame for the task then
signs the section.
2. PERMIT OFFICER Indicates the hazard potential in the equipment, tools,
work area and adjacent or associated work.
3. PERMIT OFFICER Specifies the type of protective clothing to be worn
and equipment to be carried whilst the task is
undertaken.
4. PERMIT OFFICER Lists the Supplementary Certificates raised in
connection with the Permit.
5. PERMIT OFFICER
Specifies whether or not scaffolding should be used.
PERMIT OFFICER
Examines and signs to approve the Permit.
6. PERMIT OFFICER AND Formal handover to Performing Authority, after
PERFORMING worksite inspection for Red and Yellow Permits.
AUTHORITY
Permit PERMIT CLERK The Permit is entered into the Permit Office Register,
Registry Inhibitions instituted, and Permit Number entered on
the Permit form.
7. PERFORMING Statement of completion or non-completion of task
AUTHORITY and worksite inspection with Permit Officer.
PERMIT OFFICER Acceptance by Permit Officer of state of completion
task and worksite inspection. Declaration that systems
where applicable can be returned to normal operation.
8. PERMIT CLERK Completes Permit Office Register.
It should be remembered that persons signing the Work Permit are acknowledging personal
responsibility for the standard of precautions being undertaken and the safe state of the
equipment and/or worksite.

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6 WHAT IS WIRELINE?

6.1 INTRODUCTION
Through all stages of drilling, testing, completion and production, wireline procedures will
be used extensively for work-over, data gathering and operational requirements. Modern
wireline techniques and equipment have developed and improved enormously as the whole
oil industry itself has developed.
Originally, wireline was conceived as an early method of determining the depth of a well
accurately, by lowering a flat section, graduated steel tape into the well from a hand-
operated reel.
As depths increased, the difficulties associated with this technique grew until it was no
longer safe or practicable. The tape was replaced by a circular section of slickline or
measuring line, which allowed superior sealing properties when the survey was performed
under well pressure.
The line was marked in equal increments and calibrated measuring wheels introduced.
These ‘Veeder Root’ counters are very similar to those in use today. Larger diameter lines
were introduced as new demands on the line, such as removal of deposits, installation and
removal of flow control devices were made. The grade of solid steel line has progressed to
the modern line in use today of +25,000 ft. length and extremely high tensile strength.
Downhole equipment was now being designed with the greater wireline capability in mind.
This equipment included tubing plugs, to enable the tubing to be run and pulled under
pressure, bottom hole chokes for gas wells to prevent freezing of surface flow lines caused
by choking at the surface, running straight hole survey instruments, known as ‘sypho’ and
operation of the first regulated gas lift valve, known as the Nixon valve. The Nixon valve
was opened by upward movement of the slickline, controlled at the surface by timing
devices. As the wireline was pulled upward, tools attached to the lower end opened the
valve, allowing the gas to enter the tubing from the annulus. This early method of gas lift
operations was followed by gas lift valves which could be removed and repaired or
adjusted and reset by the use of wireline tools.
The wireline winch unit has developed from a hand-operated reel or motor, driven from the
rear axle of a car, to the modern skid-mounted, self-contained module, driven electrically,
mechanically or hydraulically and fully equipped with tools and wellhead equipment to
safely service gas or oil wells under pressure.
Wireline may be referred to by a number of names. Solid single strand line may be
described as:
• Slickline
• Wireline

Multistrand wirelines are usually described as braided line.

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As well depths have increased over the years since the first measuring lines were brought
into use, accompanied by increased working loads, it has become necessary to develop
wireline having a high strength/weight ratio.
There is a need for strength to accomplish the operation without the wire breaking, and a
need to keep the diameter of the wire as small as possible for the following reasons:
• It reduces the load of its own weight
• It can be run over smaller diameter sheaves, and wound on smaller diameter
spools or reels without overstressing by bending
• It keeps the reel drum size to a minimum
• It provides a small cross-section area for operation under pressure.

The sizes of solid wireline in most common uses are: 0.108ins and 0.125ins diameter, and
are obtainable from the drawing mills in one-piece standard lengths of 18,000, 20,000,
25,000 and 30,000 ft.
The most popular material for wireline is improved plough steel (IPS), because of its high
ultimate tensile strength, good ductility, and relatively low cost. Experience indicates that
improved plough steel usually performs better than the more expensive special steel lines,
even in corrosive conditions - although then it must be used with an appropriate inhibitor
(e.g. Servo CK352 or CK356). For Sweet Wells IPS can be used with inhibitor for high
loads and long service. For Sour Wells IPS can be used with inhibitor for high loads and
short operating time.
When selecting or operating with wireline, various factors, such as the following, have
been considered:
• Physical properties
• Resistance to corrosion
• Effect of bending
• Total stress
• Care and handling.

Due to the H2S content of many wells special materials such as 0.108 ins NITRONIC-50
manufactured by Bridon Wire, or stainless steels are used. Although these are not as strong
as IPS, they have an excellent resistance to H2S corrosion.
Refer to Expro Wireline Operational Guidelines for further information.

6.2  Expro North Sea Ltd.

Wireline Module 1
The following table shows the relative strengths of IPS. (Improved Plough Steel) wire and
H2S resistant alloy wirelines: General Comparison of Grades.

Steel Specifications Strength Relative to General Corrosion

API Resistance Rating
Carbon Steel - Bright API-9A API-9A Poor
Drawn Galvanised API-9A API-9A Better
Ultra High Tensile Bridon UHT 25% Higher Poor
Stainless - 304 Type Bridon API-9A Good
316 Type Bridon 10% Lower Better than 304
Supa 60 Bridon 15/20% Lower Excellent
Supa 70 Bridon 5% Higher Excellent
Supa 75 Bridon Similar Better than Supa 70
Table 6.1

Carbon Steel Wires to API-9A

The wire is supplied on steel reels in continuous lengths. Diameter tolerance + 0.001 inch.
Torsion in all cases in accordance with API-9A.

Nominal Nominal Weight Recommended Minimum Breaking Load

Diameter per 1000 ft Minimum Pulley
Dia Bright UHT Bright
ins lbs ins lbs lbf
0.092 22.69 11.25 1547 1980
0.108 31.11 13.00 2120 2720
0.125 41.80 15.00 2840 3640
Table 6.2

Stainless Steel and Special Alloys

All stainless steel and Special Alloy wires are supplied on nylon coated steel reels in
continuous lengths, to the following Bridon specifications.
• Diameter tolerance + 0.001 ins
• Ductility wraps on own diameter - 8 minimum.

Nominal Rec’d Minimum Breaking

Load
Diameter Nett Pulley 304 316 Supa 60 Supa 70 Supa 75
Weight
per 1000 Diameter
ft
ins lbs ins lbf lbf lbf lbf lbf
0.092 22.90 11.25 1550 1400 1260 1600 1470
0.108 31.55 13.00 2100 1850 1720 2100 2030
0.125 42.26 15.00 2700 2500 2220 2600 2526
Table 6.3

 Expro North Sea Ltd. 1999 6.3

Wireline Module 1
6.2 BENDING STRESSES
The bending stresses that the line is subjected to are the most common cause of breaking
but are generally the least considered. Bending occurs whenever a line deviates from a
straight line condition, such as when it passes over pulleys or reel drum, or when it is
flexed by hand.
It is necessary to employ specific mechanical equipment, such as the reel drum, hay pulley,
stuffing box pulley and measuring wheel, when carrying out wireline operations. Each time
the line passes over a pulley it is subjected to two bending stresses - when it changes from a
straight to a curved path and again when it reverts to a straight path. It is subject to only
one when it leaves the reel drum. So, for each trip in and out of the well, the line probably
suffers a minimum of fourteen bending cycles.

Note: To minimise the effect of bending stresses on the wireline, 50-100 ft. is
normally cut and discarded every time a new rope-socket is tied. This
action will subject a different part of the wireline to bending stresses.

6.4  Expro North Sea Ltd.

Wireline Module 1
6.3 RE-SPOOLING
The life span of any wireline can be extended by using correct spooling procedures. The
new wire should be spooled on to the unit drum with 250-400 lbs strain on it. Five to seven
bedding wraps of carefully aligned wire are recommended to provide a firm base. This also
indicates during subsequent wireline operations that only a small amount of wire remains
on the drum.
Correct procedures for spooling new wire on a reel are shown overleaf to minimise stress
in the line.

Spool Reel Spool Reel

C o rrect M eth o d

Spool Reel Spool Reel

Inco rrect M eth od

Figure 6.1 - Re-Spooling

6.4 HANDLING AND STORAGE

Although steel wireline has a high strength-to-weight ratio, it still requires proper handling
and storage. IPS should be stored with a lubricant covering over the surface of the wire
(i.e. grease, grease paper).
If not crated, wireline spools should be lifted with a nylon sling to avoid damage to the
wire.
When a wireline job is completed, the wire should be lubricated and covered to protect
against corrosion.
Alloy wire spools should also be kept covered as they are not totally immune to
corrosive/erosive atmospheres.

 Expro North Sea Ltd. 1999 6.5

Wireline Module 1
6.5 GENERAL SAFETY PRECAUTIONS
1) There is a certain amount of tension in a coil of wire, so when it is unfastened, care
should be taken to make sure that the leading end does not lash out. Ensure that the
free end is always under control.
2) Ensure that hard hats, safety boots/shoes, coveralls, safety glasses, gloves are worn.
3) Never carry out flame cutting or welding operations near reels of wireline. Heat or
metal spray coming in contact with the wire could change the condition of the steel
significantly and lead to early failure in use.
4) Throughout all wireline operations the immediate area around the path of the wire
must be cordoned off.

Damage and abuse may not always be obvious, or the significance be appreciated, and
effects are cumulative. There are three main categories:
• Mechanical damage
• Corrosion
• Wire winding practice.

These are summarised in the following table under fault, cause, result and correction.

Fault and Causes Results Correction

Damage to reels: Wire snapping during Use sling when handling reels
Bending of flanges, distortion unwinding. or use ramps. Do not drop.
of barrel. Caused by
dropping.
Corrosion in store: Under worst conditions there All types of wire: store reels
Carbon steel wire is oiled but, will be pitting of the surface upright (on edge) on a level,
if stored uncovered, corrosion and local reduction in solid base in dry, covered
will develop at varying rates strength. Slight damage at conditions. If a permanent
depending on climate. Alloy this stage, which may be store is not available, support
steels are for use under scarcely visible, could reels off the ground under
corrosive conditions but they increase the risk of alloy wire waterproof cover. The latter
are not completely immune corrosion in service. should be kept out of contact
and, where there are wind with the wire and fastened
blown salts, slight damage down just clear of the ground to
may occur. allow air to circulate and
minimise condensation.
Corrosion in service: There may be development of When rewinding wire, wipe off
There are inevitable hazards surface pitting. At worst there well contamination. If carbon
of well conditions and may be stress corrosion or steel wire reels are to be put
environment. hydrogen embrittlement back into store, re-oil the wire
causing brittle failure. during rewind. Do not leave
any wireline downhole unless it
is necessary.
Wire winding practice:
Wire damage may be caused at various stages in winding onto the service reel from the supply
reel or in rewind during use. To ensure good spooling, it is recommended that an intermediate
capstan is used between the supply reel and the wireline unit drum to develop a high line tension
without risk of cutting down. Practices are followed in the running of wirelines that have to
strike a balance between operational convenience and wireline life. To the user , some of the
possibilities listed here may seem unlikely to happen but they are given so that, if any should
occur, their significance will not be ignored.

6.6  Expro North Sea Ltd.

Wireline Module 1

1. Uneven winds: Wire pullsdown between Maintain a regular traverse of

Variable tension and/or poor adjacent turns preventing free the wire across the full width of
control or wire traversing the running, causing snags and the barrel to give uniform build
barrel. possibly wire breaks. up of layers. Course pitch and
tension during winding onto the
reel will minimise the risk of
the wire pulling down.
2. Loops and bends: Overrunning with the risk of Whatever the method used to
Insufficient braking on the snarls forming in looped wire. keep the wire under tension
supply reel. Even if the snarl is during winding, a brake on the
straightened out by hand, supply reel is desirable so that
there can be a significant too much slack wire does not
reduction in strength. appear between the two reels.
Overrun wire may be pulled
over a reel flange and be
sharply bent.
Fault and Cause Result Correction
3. Wire abrasion: Reduction in wire strength as Keep tension and always wind
Rubbing on the ground caused a result of loss of cross- from ‘top’ to ‘top’ of reels. In
by slack wire. sectional area of steel. service, rewind on top of the
Rubbing on reel side caused Reduction in cross-sectional reel. Angle of the wire during
by incorrect traversing. area. traverse and total traverse must
be controlled.
4. ‘Wild’ wire: Wire may be difficult to Always wind the wire in the
Cause by slack winding or by control and lead to tangles and direction of its natural
reversing the natural curvature snarling. curvature. Never wind from
of the wire. the top of one reel to the
underside of the other.
5. Wire indentation: Reduction in strength. Avoid excessive tension in
Caused by ‘cross-cutting’ winding and excessive ‘jarring’
between layers of wire. when operating downhole
tools.
6. Friction on pulleys: Embrittlement of wire surface. Avoid excessive ‘jarring’.
Possible during ‘jarring’. Shock loads can produce high Cutting the wire between uses
surges out of all proportion to minimises the chance of
the assumed loads on the wire cumulative damage.
and may cause failure.
7. Fatigue cracks: Wire failure, particularly if Ratio of pulley and wire
Caused by repeated bending other factors noted above are diameter should preferably be
under high stress. contributing. 120:1 to reduce the significance
of bending.
Table 6.4

 Expro North Sea Ltd. 1999 6.7

Wireline Module 1
6.6 WIRELINE TORSION TESTER
The portable torsion tester is designed to be able to test wirelines in the field in compliance
with API 9A and the Health and Safety at Work Act 1974.

6.6.1 Objective
To measure the number of twists an 8 ins long sample piece of wireline can withstand
before breakage occurs. Recording these results in a log allows a performance curve to be
drawn showing the lifespan of a wireline in relationship to it's usage. This highlights the
current em-brittlement in a line prior to carrying out further wireline operations.

6.6.2 Procedure
1) Pull approximately 50 ft of wire from the drum, cut a small length and prepare a
specimen (see specimen configuration). See Figure 6.3.
2) Place the specimen through the jaws of the tester. Set the jaws at the appropriate
marks which provide the wire gauge length of 8 ins. between the jaws.
3) Tighten down the Allen holding screws sufficiently to hold the wire in place during
the test. See Figure 6.4.
4) Close the tester lid and secure the latch. See Figure 6.2.
5) Rotate the handle at a constant rate of approximately 60 turns per minute (60 rpm)
until the wire parts. Count and record the number of turns taken to part the wire and
if the total of rotations is not a whole number, round up if the part rotation is equal to
or greater than a half turn.
6) Unlatch and open lid, (caution – wire will be hot), remove the wire ends from the
jaws and inspect for a lean shear (see fracture analysis). Record the number of turns
or rotations into the log book and any relevant information from the analysis.
7) The torsion test should be carried out at the start of any wireline operations and
thereafter every time a new rope socket connection is made. If the number of
rotations is less than operators or manufacturers guidelines, refer to wireline test
analysis.
8) The torsion test recordings should be entered into the log book along with the other
wireline history.

6.8  Expro North Sea Ltd.

Wireline Module 1
Ductility Tester
TORSION REQUIREMENTS OF THE API-9A SPECIFICATION
Nominal Wire Diameter 0.092 0.108 0.125
Minimum Number of Twists in 8” 23 19 17
Table 6.5

WARNING: ALWAYS WEAR EYE PROTECTION WHEN USING WIRE

TESTER.

Date Wire Spooled Total Length 20,000 ft

Date Type of Job No. of Footage No of Type of Wire Balance
Runs Run Turns Break Cut Off Remaining
(ft)
13-11-94 Ball/ v Change 8 2,400 23 Good 50 19,950
18-11-94 Gauge Rings + 4 14,000 21 Good 50 19,900
Tag Fill
20-11-94 Set Plug TBG 5 8,500 21 OK 50 19,850
Test
9-12-94 Bailing 16 11,250 17 OK 500 19,350
12-12-94 Fishing 14 12,100 15 Good 300 19,050
25-12-94 Plugs For 8 10,800 13 OK 500 18,550
Completion
Recommended
Wire Change
Table 6.6

The above chart is only for comparison purpose. In real life conditions wire would
probably last much longer.

6.6.3 Slickline Operation And Maintenance

To ensure the wireline performs effectively throughout its working life it is imperative it is
kept in optimum condition. For this purpose a log book shall be kept showing up-to-date
details of the following:
• Date wire spooled onto reel.
• Amount of wireline spooled on.
• Amount of bedding wraps.
• Length of exposure to well fluids.
• Type of well fluids.
• Depth of wireline operation.
• Maximum strain exerted on the wireline during the operation.
• Amount of wireline cut off after the operation.
• Amount of wireline remaining on the reel.
• Torsion test result at the cut off point, if applicable

 Expro North Sea Ltd. 1999 6.9

Wireline Module 1
Operation
a) Ascertain whether the wireline on the drum is suitable for the working
environment expected. If H2S or CO2 is encountered with plough steel wireline, a
chemical inhibitor shall be used.
b) Ascertain from the log book whether there is sufficient wireline on the drum to
perform the deepest operation.
c) Torsion test the wireline prior to rigging up and after re-tying the wireline rope
socket.
d) Ensure the path of the wireline is unrestricted during all operations.
e) Minimise the amount of hay pulleys in the rig up to reduce bending stresses
through out the operation.
f) Use the recommended hay pulley diameters for the size and type of wireline in
service to reduce the bending and fibre stresses in the wireline.
g) The extent of jarring up operations should be restricted to 50% of the breaking
strain of the wireline when new.
h) A line wiper shall be used to remove all well fluids from the wireline while pulling
out of the hole.
i) Apply a light coat of oil to the wireline while pulling out of the hole.
j) Ensure the wireline is protected with a film of grease or denso-tape during periods
between wireline operations.

6.10  Expro North Sea Ltd.

Wireline Module 1

Figure 6.2 - Linetech Torsion Tester

 Expro North Sea Ltd. 1999 6.11

Wireline Module 1
6.6.4 Torsion Test Specimen Configuration
Unlike conventional torsion testers, this machine has been designed to test prepared
wireline samples of a specific length and configuration:

5/8"

10 1/4"

Figure 6.3 - Test Specimen Configuration

The reasons for selecting a wire sample of this configuration is that, in conjunction with the
fixed machine dimensions, a constant test gauge length of 8 ins. is always achieved
between the jaws of the machine when the wire sample is clamped in position which
ensures accurate testing and compliance with Section 3.10 of the API 9A specification.
The purpose of the right angled bends, formed on each end of the wire test piece, are to
prevent slippage of the wire in the jaws during rotational twisting. This technique permits
the use of flat-faced jaws, which minimise the likelihood of invalid tests due to sample
damage and jaw failures.

5/8"

8"

10 1/4"

Figure 6.4 - Wire in Flat Faced Jaw

6.12  Expro North Sea Ltd.

Wireline Module 1
6.7 WIRELINE TEST ANALYSIS
6.7.1 Acceptance
If the number of turns is satisfactory, the test piece is deemed to have passed the test,
irrespective of the position of the failure. If the number of turns does not satisfy the
requirements of the specification and if failure is within 1/8 ins of the grips, the test shall be
considered as invalid and shall be repeated.
If, when making any individual test, the first specimen fails then two additional specimens
shall be tested. The average from any two will then be taken as the value to represent the
wire. If these also fail, 500 ft of wire will be pulled from the drum and the test repeated. On
further failure of the tests, a maximum of two more 500 ft lengths shall be removed and
tests conducted. If after this the wireline still fails the tests, the Wireline Supervisor should
be informed in order to make a decision on the disposition of the line.

6.7.2 Torsion Fracture Analysis

Few people appreciate the significance of the torsion test as a definitive wire quality arbiter
for carbon steel wirelines. It is not just the number of twists to failure that is important, but
more specifically, whether the material exhibits a "ductile" or a "brittle" primary fracture.
In general, three types of primary wire fracture may be encountered at the conclusion of a
torsion test, these are categorised as follows.

6.7.3 Fracture Classification

Grade 1 Fracture without Secondary
Breaks.
After testing, the sample should contain
a single fracture which is square ended
(sometimes called a "Ball and Socket"
break). Figure 6.5 There should be no
evidence of spiral splitting on the sample
and no secondary fractures.
This type of fracture is characteristic in
wire a suitable condition for continued
use. It is usually associated with a high
number of turns before failure.

Figure 6.5 - Single-Square Ended Primary Fracture

 Expro North Sea Ltd. 1999 6.13

Wireline Module 1
Grade 1 Fracture with Secondary Breaks
Sometimes a grade 1 fracture may be
accompanied by a secondary helical-
shaped fracture. See Figure 6.6. This
secondary fracture is a result of the
instantaneous release of stored energy
when the primary fracture occurs. It is
termed a "recoil" fracture.
Although a recoil fracture indicates a
slight reduction in torsional strength and
ductility, it can be discounted. The main
concern is the primary fracture and this is
a true reflection of the wire condition.

Figure 6.6- Single-Square Ended Primary

Fracture with Secondary Breaks

Grade 2 Fractures
Although containing a square-ended
break, a grade 2 sample primary fracture
may be slightly stepped. Figure 6.7.
Secondary helical fractures may be
present and slight spiral splitting may also
be in evidence.
This type of primary fracture is usually
associated with a lower number of turns
before failure.

Figure 6.7- Slightly Stepped Primary

Fracture

6.14  Expro North Sea Ltd.

Wireline Module 1
Grade 3 Fractures
The primary fracture will show a severely
stepped or helical type break, usually
associated with secondary fractures.
Figure 6.8 Spiral splitting will almost
certainly be present along with localised
twisting.
A secondary break is not usually present
as the primary break is associated with a
low number of turns to failure.
This sample would be unacceptable for
further use. Re-testing would be required
after spooling off approximately 500 ft of
wire.

Figure 6.8- Single -Helical Spear Type

Fracture

6.7.4 General Guidance Notes

It should be noted that any torsion test performed relates only to the test piece and does not
guarantee the quality of the remaining length of wireline.
In the event of obtaining Grade 2 or Grade 3 type fracture characteristics two repeat tests
shall be performed. If the quality of a wireline is variable, it is permissible to cut off a
length (say 200 ft) and re-test. Two re-tests should both give Grade 1 type fractures. This
procedure may, if necessary, be repeated since it is well known that the ductility of a
wireline deteriorates more rapidly at bottom hole temperatures.

 Expro North Sea Ltd. 1999 6.15

Wireline Module 1

6.16  Expro North Sea Ltd.

Wireline Module 1
7 QUICK UNIONS

7.1 INTRODUCTION
The connections used to assemble the lubricator and related equipment are referred to as
Quick Unions. They are designed to be quickly and easily connected by hand.
The box end receives the pin end, which carries an O-ring seal. The collar has an internal
ACME thread to match the external thread on the box end. This thread makes up quickly
by hand and must be kept clean. The O-ring forms the seal to contain the pressure and
must be thoroughly inspected for damage and replaced if necessary. A light film of oil or
grease on the pin and O-ring helps in the make up of the union and helps to prevent cutting
of the O-ring. A coating of light oil may be used on the threads (not grease). Pipe
wrenches, chain tongs or hammers must never be used to loosen the collar of the
union. If it cannot be turned by hand, all precautions must be taken to make sure that the
well pressure has been completely released.

 Expro North Sea Ltd. 1999 7.1

Wireline Module 1

Figure 7.1 – ‘O’ Ring Seals

7.2  Expro North Sea Ltd.

Wireline Module 1
NOTE: In general, unions that cannot be loosened easily by hand may indicate
that pressure may be trapped inside. Ensure that all pressure is released
“before” unscrewing the union.

NOTE: Before making up quick unions the ‘O’ ring and threads should be
checked.

The collar of the union will make up by hand with the pin end, when the O-ring has been
shouldered against the box end. When the collar bottoms out, it should be backed off
approximately one quarter turn to eliminate any possibility of it sticking due to friction
when the time comes to disconnect it.
Rocking the lubricator to ensure it is perfectly straight will assist in loosening the quick
union. Make sure that tugger lines and hoists are properly placed to lift the lubricator
assembly directly in line over the wellhead.
The two most common types of quick union are manufactured by Otis and Bowen. See
Figure 7.2.

 Expro North Sea Ltd. 1999 7.3

Wireline Module 1

Figure 7.2 - Otis and Bowen Quick Unions

Quick Union Threads Per Max. Working H2S Inside Dia. Seal Dia. Collar Dia.
Thread (ins) Inch Pressure (psi) Service (ins) (ins) (ins)
5.000 4 5,000 Yes 2.500 3.500 5.77
5.750 4 10,000 Yes 3.000 4.000 7.02
6.000 4 5,000 Yes 4.000 4.875 6.75
6.500 4 5,000 Yes 4.000 4.750 7.52
6.500 4 10,000 Yes 3.000 5.138 7.52
8.250 4 5,000 Yes 5.500 6.188 9.52
8.375 4 10,000 Yes 4.000 5.250 9.55
8.375 4 5,000 Yes 6.375 7.500 9.77
9.000 4 10,000 Yes 5.000 6.750 10.52
9.500 4 5,000 Yes 6.375 8.000 10.52
11.500 4 10,000 Yes 6.375 8.250 13.02
Table 7.1 - Standard Otis Quick Union

7.4  Expro North Sea Ltd.

Wireline Module 1

Quick Union Threads Per Max. Working H2S Inside Dia. Seal Dia. Collar Dia.
Thread (ins) Inch Pressure (psi) Service (ins) (ins) (ins)
4.750 4 5,000 Yes 2.500 3.750 6.02
5.500 4 x 2 st 5,000 Yes 3.000 4.375 6.34
6.312 4 10,000 Yes 3.000 4.375 7.52
6.000 4 x 2 st 5,000 Yes 3.000 4.875 6.77
8.250 4 x 2 st 10,000 Yes 4.000 6.000 9.46
7.000 5 5,000 Yes 4.000 5.250 7.77
8.250 4 x 2 st 5,000 Yes 5.000 6.750 9.52
8.875 4 x 2 st 10,000 Yes 5.000 6.500 10.40
9.875 4 x 2 st 5,000 Yes 6.375 8.000 10.90
Table 7.2 - Standard Bowen Quick Unions

7.1.1 Wellhead Adapter (Tree Adapter)

All Wellhead Adapters are crossovers from Xmas tree to the bottom connection of the
Wireline Valve or Riser. It is important to check that the correct type of threads with
appropriate pressure ratings are used on the top and bottom of the adapter.
Three types of Wellhead Adapter; See Figure 7.3, are in common use:
• Quick Union to Quick Union.
• API Flange to Quick Union.
• Acme Thread to Quick Union.

Figure 7.3 - Wellhead Adapters

 Expro North Sea Ltd. 1999 7.5

Wireline Module 1
7.1.2 Pump-In Tee
A Pump-in Tee; see Figure 7.4, consists of three main parts:
• A Quick Union box end.
• A Quick Union pin end.
• A Chiksan/Weco type connection.

The Pump-in Tee, can be placed between the Wellhead adapter and the wireline BOP.
Therefore, Quick Union sizes and pressure ratings must be compatible with all surface
equipment.
Pump-in Tees may be required as part of a wireline rig-up. By connecting a kill-line to the
Chicksan/Weco connection, the well can be killed in an emergency situation. The line can
also be used to pressure test or release pressure from the surface equipment.

NOTE: On some locations, the pump-in tee will be part of the wellhead adapter.

Figure 7.4 - Pump-in Tee

7.6  Expro North Sea Ltd.

Wireline Module 1
7.1.3 Wireline Blow Out Preventer (BOP)
a) Description
A blowout preventer (BOP) or wireline valve must always be installed between the
wellhead/Xmas tree and wireline lubricator. The BOP is a piece of safety equipment that
can close around the wireline and seal off the well below it. This enables the pressure to be
bled off above it, allowing work or repairs to be carried out on equipment above the BOP
without pulling the wireline tools to surface. A positive seal is accomplished by means of
rams which are manually or hydraulically closed without causing damage to the wire.
Hydraulically actuated BOPs are more commonly used because of the speed of closing
action and ease of operation. Often during an emergency, the BOP is not easily accessible
to allow fast manual operation and therefore remote actuation is preferred.
Single or dual ram BOPs are available in various sizes and in a full range of working
pressure ratings. Dual rams offer increased safety during slick line work and allow the
injection of grease to secure a seal on braided wireline. They are used particularly in gas
wells, or wells with a gas cap at surface.
BOPs are fitted with equalising valves that allow lubricator and well pressure to equalise
prior to opening the rams when wireline operations are to be resumed. Without this, if the
BOP rams were to be opened without first equalising, the pressure surge can blow the tool
or wire into the top of the lubricator, causing damage or breakage.
Care must be taken with hydraulic BOPs to ensure that hydraulic pressure is kept to a
minimum when closing Rams.
Example: 7” BOP with 7” pistons closed with 1000 psi per piston.
Force = Pressure x Area
π D2
Area =
4
3.142 x 72
= 4
= 38.48 in2
F =PxA
= 1000 (Piston Pump Pressure) x 38.48 (Piston Area)
= 38,480 lbs per Ram/Piston
38.480
= 2240 = 17.17 Tons Per Piston

At this pressure, damage can occur to the stem, keyways and possibly guide inserts.

NOTE: Keep the Piston Pressure to a minimum. (Do not exceed operating
pressure)

 Expro North Sea Ltd. 1999 7.7

Wireline Module 1
WARNING: Since they are such a vital component controlling the safety of the well,
it is important that bop's are regularly pressure and function tested.
tests must be carried out prior to transport offshore, before each new
wireline operation, and after any redress or repair of the bop.

b) Use of BOPs
• To enable well pressure to be isolated from the lubricator when leaks develop
etc. without cutting wire by closing the master valve.
• To permit assembly of a wireline cutter above the rams.
• To permit dropping of wireline cutter or cutter bar.
• To permit "stripping" of wire through closed rams though only when absolutely
necessary.

c) Description of Operation
A mechanical or hydraulic force is applied to close the rams to seal against well pressure.
The sealing elements are arranged so that the differential pressure across them forces them
closed and upwards, assisting in the sealing action.

CAUTION: Wireline BOP's will hold pressure from below only.

d) Equalising Valve
Permits equalisation of pressure from below the closed rams, after bleed off of the
lubricator. The equalising valve must be opened and closed prior to use.
Check that the equalising assembly is not inverted and that the Allen screw is towards the
bottom of the BOP.

7.8  Expro North Sea Ltd.

Wireline Module 1

Figure 7.5 - Wireline BOP

 Expro North Sea Ltd. 1999 7.9

Wireline Module 1
7.2 WIRELINE BOP
7.2.1 Pressure Testing Of Wireline BOP
Prior to BOP being used in operations they must first be fully function tested and pressure
tested.

Function testing
1) Ensure BOP rams are in the fully open position
2) Drift BOP with the appropriate size drift
3) Close BOPs, visually confirm BOP s are closed
4) Re-open BOPs

Pressure testing
1) With the BOPs installed (on test stump or rig-up)
2) Close BOP rams
3) Open the equalising valve on the BOP and fill with test fluid to purge the air from the
system then close the equalising valve
4) Low pressure test from below to required test pressure and hold for 3 minutes
5) High pressure test and hold for 15 minutes
6) Bleed pressure to zero
7) Open equalising valve prior to hydraulically opening the rams

NOTE:- Refer to Expro Operational Guidelines

Maintenance
Maintenance must be carried out on a regular basis, or after every time a BOP has been
operated against wire.
BOPs must be fully stripped down and all seals and sealing faces inspected for damage.
Any damaged seals must be replaced, on completion of maintenance BOP must be function
tested and pressure tested.

Relationship between test pressure and working pressure

All surface equipment should be manufactured and fabricated in accordance with
applicable provisions of the code of pressure piping, ANSI BSI series. ASTM. AISI or
API specification materials, other than those acceptable under ANSI BSI series piping
codes, may be used provided that they are satisfactory for the intended service and welding
procedures and welders are qualified for the material used.
A drift, visual and pressure test check of all sections of the lubricator should be made at
intervals not to exceed 6 months. The pressure test, using cold water, should be made at
least one and one and a half times the lubricator working pressure should not exceed its
rated test pressure. The wireline BOP should be tested in both the open and closed
positions.

7.10  Expro North Sea Ltd.

Wireline Module 1
7.3 LUBRICATORS
The lubricator is in effect a pressure vessel situated above the Xmas tree, subject to the
wellhead shut-in pressure and also test pressures. For this reason it must be regularly
inspected and tested in accordance with statutory regulations.
All lubricator sections and accessories subject to pressure are to be banded with stainless
steel, with maximum working pressure, test pressure, and date and rating of last hydrostatic
test.

a) Description
A lubricator allows wireline tools to enter or be removed from the well under pressure.
The lubricator is a tube of selected ID and can be connected with other sections to the
desired length by means of "quick unions".
The following factors govern the selection of lubricators:
• Shut-in wellhead pressure and well fluid
• Wireline tool diameter
• Length of wireline tools.

The bottom lubricator section normally has one or more bleed off valves installed; a
pressure gauge can be connected to one of the valves to monitor pressure in the lubricator.
If the lubricator has no facility to install valves then a "bleed off sub", a short lubricator
section with two valves fitted should be connected between the BOP and lubricator.

NOTE: The minimum length of the lubricator must be longer than the maximum
length of the toolstring to be run/pulled.

b) Construction
Quick unions connect lubricator sections together and to the BOP. Lubricators for normal
service (up to 5000 psi) can be made of carbon or manganese steel. Over 5000 psi
consideration shall be given to sour service as quantities of H2S can be absorbed into the
steel of the lubricator body and heat treatment becomes necessary.
All lubricators must have full certification from the manufacturer or test house.
A standard colour code identifies different pressure ratings of lubricator. This code is only
standard for each company and is not an industry standard. (Colours may vary from
company to company).

 Expro North Sea Ltd. 1999 7.11

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Figure 7.6 – Lubricators

7.12  Expro North Sea Ltd.

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e.g. Basic colour of surface equipment Blue, with a band of following colour:
Pressure Rating Band Colour
1000 psi Silver
1440 psi Yellow
5000 psi Red
7500 psi Brown
10,000 psi Black
15,000 psi Purple
Sour Service Green
Table 7.3 – Standard Colour Codes

 Expro North Sea Ltd. 1999 7.13

Wireline Module 1
7.3.1 Injection Sub
An injection sub; see Figure 7.7, resembles a short lubricator section with quick union
connections at either end.
The injection sub should be installed immediately below the stuffing box in the surface rig-
up. A check valve is installed in the body of the injection sub as part of the injection line.
The purpose of the check valve is to contain well pressure in the event of hose failure and
must be in working order.
The injection sub is used to introduce fluids into the lubricator during wireline operations
to counteract one or more of the following :
• Corrosive environments (e.g. H2S).
• Hydrate formation (glycol injection/methanol injection).
• Dry gas conditions.

Figure 7.7 - Injection Sub

7.14  Expro North Sea Ltd.

Wireline Module 1
7.4 CUTTER VALVE
Description
The cutter valve is a surface mounted valve permitting tight closure of the well during thru-
tubing wireline, electric line or coiled tubing operations. The valve will simultaneously cut
wire and coiled tubing, closing in the well, without the need to manipulate the Xmas tree
master valve. Opening and closing of the valve is achieved by applying pump pressure, it
is not a failsafe device. The ball and seat are fitted with replaceable cutting inserts,
minimising the risk of damage to the ball and seat assemblies during cutting operations.

Application
The valve is installed on the wellhead prior to performing wireline or coiled tubing
operations, and in an emergency, is closed instead of the master valve.

The valve is normally used as a self-contained unit, with a dedicated accumulator, but may
also be incorporated as part of a well service control system. (Well control – See section
10).
FEATURES BENEFITS
Compact Design Allows safe installation when wellhead access
is restricted.
Cut and seal capability Automatic containment of well pressure, once
the cut is made and the valve is closed.
Replaceable cutter inserts Reduced maintenance costs with quicker
turnaround time during redress.
T-Seal Technology Improved seal life with lower frictional losses.
4140 H2S Service Ball H2S Service as per NACE.
Table 7.4 – Cutter Valve Features

7.5 WORKOVER VALVE

Description
The workover valve is a surface mounted valve, permitting pressure tight closure of the
well during through-tubing work. (Slickline, electric line etc.) the valve can be made to
have wire cutting capability, this would allow the valve to cut through lines up to 7/32” in
size. However this should only be used in an emergency. e.g. an abandon platform alarm.

Application
The valve is placed onto a quick union connection, usually during a work over or fishing
operations and can be closed in an emergency i.e. the well fluids coming back on line
during a work over.

 Expro North Sea Ltd. 1999 7.15

Wireline Module 1
7.6 STUFFING BOX
The stuffing box is a sealing device connected to the top of the lubricator sections. It allows
the wireline to enter the well under pressure and also provides a seal should the wireline
break and be blown out of the packing. The stuffing box will cater for all sizes of slickline
but the size of the wire must be specified to ensure the correct packing rubbers, upper +
lower gland, and BOP are installed.
If the wireline breaks in the well, the loss of weight on the wire at surface allows well
pressure to eject the wire from the well. To prevent well fluids leaking out the hole left by
the wire, an internal blow out preventer plunger is forced up into the stuffing box by well
pressure and seals against the lower gland.
A packing nut and gland located at the top of the stuffing box can be adjusted to tighten the
packing and lubricate the wireline. Hydraulic controlled packing nuts are available to ease
operation should the packing require to be tightened during wireline operations.
There are a variety of stuffing box packing materials available to suit well conditons and
need to be selected accordingly.
For slickline operations the top sheave is normally an integral part of the stuffing box, this
reduces the rig up equipment required and the large 10 or 16 inch sheaves can handle the
larger OD wire with less fatigue and breakdown.
Wireline sealing devices fulfil one of two functions:
• Pressure containment (sealing)
• High pressure containment on braided line.

For solid wirelines, only pressure-containing stuffing boxes are utilised. The standard
stuffing box is available in 5000 psi and 10,000 psi pressure ratings. Higher pressure
ratings are now also available.
The essential function of the wireline stuffing box is to ensure containment or sealing off
around solid wirelines, whether stationary or in motion, at the upper end of the lubricator
during wireline operations. In addition, most stuffing boxes contain a BOP plunger which
seals off flow in the event that the wireline breaks and is forced out of the packing section.
A swivel-mounted (360 free movement) sheave wheel and guard are fitted to the top half of
the stuffing box. The wheel is positioned so as to maintain the passage of the wire through
the centre of the packing rubbers.
The sheave guard on the stuffing box is designed to stop wire jumping out of the groove in
sheave when jarring.

7.16  Expro North Sea Ltd.

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Figure 7.8 - Stuffing Box

 Expro North Sea Ltd. 1999 7.17

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7.7 HYDRAULIC PACKING NUT
The hydraulic packing nut assembly is designed for a standard wireline stuffing box to
allow remote adjustment of the packing nut. This method is a safe and convenient way of
regulating the packing nut, and is made by means of a hydraulic hand pump and hose
assembly from a ground position.

a) Benefits
• The need for a man to climb a lubricator is eliminated.
• The hand pump is positioned away from the nut itself, and possible escaping
well fluid.

b) Operation
The hydraulic packing nut assembly includes a piston which has a permissible travel of 0.4
ins enclosed in a housing. The housing has a NPT connection for a hydraulic hose.
The area above the piston is arranged so that when hydraulic pressure is applied to this
area, the piston is forced downward against the force of the spring. The downward action
of the piston is transmitted to the upper packing gland causing the stuffing box packing to
be squeezed around the wireline, sealing off well fluids within the stuffing box. Care must
be taken that the minimum hydraulic pressure is used to seal the wire. (Overpressuring will
cause premature wear on the stuffing box packing.)

7.18  Expro North Sea Ltd.

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Figure 7.9 - Hydraulic Stuffing Box

 Expro North Sea Ltd. 1999 7.19

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7.20  Expro North Sea Ltd.

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8 WIRELINE UNIT

The wireline winch has progressed from a hand-operated reel, driven by a belt and
propelled by a pulley attached to the rear axle of a car or pick-up to the present day
truck/skid mounted units. Today's wireline operations are often complex and demanding
with wireline work being carried out at ever increasing depths. To meet these demands, the
modern wireline unit has been developed to provide increased power and transportability
while meeting strict safety requirements.
A wireline winch is used as the means of lowering and raising toolstrings in wells that
require wireline servicing.
A winch will consist of these major assemblies:
• Wireline Drum
• Controls
• Combined Winches / Power Pack

The drum assembly can be single or double, the double drum offering the facility of
running two sizes of wireline from one winch e.g. 0.108 slickline and 3/16 ins braided line
or 0.108 ins slickline and 7/32 monoconductor, for electric line operations etc. A wireline
measuring head is installed as part of the unit assembly; head design will be dependent on
wire diameter and type.
The most common found power units to drive wireline winches are diesel powered
hydraulic systems. Electrically powered winches are also used in some areas. (Both of
these power packs are discussed later in this Section). Available hydraulic power must be
sufficient to support lengthy jarring operations; the unit has to be compact for offshore
locations and satisfy zoning regulations for hazardous area use. The power pack and winch
may be combined into one unit, or separate components may be utilised which require the
connection of hoses to complete the hydraulic circuit.
Regardless of winch design, certain basic controls are common to all types of unit.
Additional controls and instrumentation are installed to ease winch operation and will be
dependent again, on the type of unit used.
Basic controls/instruments are:
• Drum brake - to keep drum stationary or used when jarring.
• Direction lever - to select rotation direction of drum.
• Gear Box - to select speed of drum rotation. (usually 4 gears)
• Hydraulic control valve (double A valve) - to control speed of drum rotation.
• Weight indicator - to measure strain on wireline.
• Counter/Odometer - to indicate wireline depth.

Many wireline winches are equipped with a spool-off and cat-head assembly. Hydraulically
operated, this provides a facility to spool wire off or onto the wireline drum.

 Expro North Sea Ltd. 1999 8.1

Wireline Module 1

Figure 8.1 - Modern Self-Contained Wireline Unit

8.2  Expro North Sea Ltd.

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Figure 8.2 - Wireline Unit Controls

 Expro North Sea Ltd. 1999 8.3

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8.1 HAY PULLEY AND WEIGHT INDICATOR

8.2 HAY PULLEY

a) Description
There is normally only one hay pulleys used, its purpose being to change the direction and
level of the wire from vertical at the top of the lubricator to horizontal at the level of the
wireline unit.
The hay pulley is positioned generally at the wellhead using a pad eye and a certified sling
on offshore locations to guide the wireline from the stuffing box to the wireline unit.
The hay pulley should be so positioned that the wireline goes through an angle of 90° at the
wellhead or lubricator/riser as this is necessary to ensure accurate weight indicator readings
when the hay pulley is attached to the wellhead via a weight indicator. In addition the
location of the hay pulley must be such that wireline handling when jarring up by hand,
hand feeling of the wireline toolstring into the lubricator or when pulling out of the well,
etc. can be readily accomplished. It is also important to secure the hay pulley as close as
possible to the wellhead or riser in order to avoid lateral loading of the lubricator during
heavy jarring operations. Securing of the hay pulley to the wellhead must be accomplished
by means of a chain or a wire sling, never rope. The hay pulley should be installed with the
lock pin facing upwards to ensure that it cannot fall out during wireline operations. Sheaves
are manufactured to suit the wireline size.
The sheave diameters for well measuring lines should be as large as the design of the
equipment will permit but not less than 120 times the diameter of the wire, otherwise cold
working of wireline material will occur, resulting in premature failure.
The hay pulley generally has a hole for the attachment of a line wiper which is used to
remove corrosive liquids and dirt from the line as it is spooled onto the drum.

b) Maintenance
Always check the shackle connection and the swivel for wear and tear and replace any
worn parts as the connection is subject to high shock loading and the pulley can cause
severe injuries if it breaks loose.

8.4  Expro North Sea Ltd.

Wireline Module 1
8.3 WEIGHT INDICATOR
8.3.1 Introduction
a) Description
Weight indicators are instruments which measure the tension placed on the wireline at the
surface. There are various types but all are either hydraulic or electronically operated. The
weight indicators commonly used are :
• The Martin Decker with the tree mounted load cell
• The unit-mounted electronic type as used in the K winch.

b) Martin-Decker Load Cell

The most often-used weight indicator is the Martin Decker which is completely hydraulic.
The sensing load cell is attached to the Xmas tree by a sling and a heavy duty hose carries
the pressure to the fluid filled gauge.
The load cell is provided with a connection at the top to attach to the hay pulley and at the
bottom to attach to the Xmas tree forming a pull at 90°. The system is calibrated to this
angle of pull and accuracy will be marginally affected if this angle is not true but the
sensitivity of the system is always maintained. The load gap is maintained by hydraulic
fluid, so if the fluid should leak out and the gap closes, the gauge readings will be incorrect.
The gauge is a 6 ins diameter fluid filled instrument which can be fastened onto the winch.
A damper is provided on the gauge to set the pointer motion to the required sensitivity. The
fluid filled case eliminates severe vibrations, lubricates and protects the working parts.
In addition to preventing the overloading of the wireline the weight indicator will also
show changes in tension due to:
• Fluid levels or changes in fluid density
• Jar action
• Position of downhole equipment.

A different Martin Decker weight indicator is used for 3/16 ins. line because of the higher
pull which can be exerted. The load cell for this instrument has a smaller cross-sectional
area in the diaphragm and is matched to the higher range dial (gauge). The gauge load cell
cannot be interchanged.
Maximum loading(standard) = 2000 lbs (888 DaN)
3
/16 ins Unit = 4000 lbs (1777 DaN)

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c) Filling with Hydraulic Fluid
Fluid loss can occur due to leaks or punctured hose etc. and occasionally the system needs
to be refilled.
1) The fluid pump is connected to the filling port at the gauge manifold and the bleed
off screw in the load cell loosened.
2) With the pump chamber full of hydraulic fluid and the hose laid out fully, the pump
is slowly stroked pumping the fluid into the system.
3) Check the bleed off port for returns and if there is any air in the system. Keep load
cell higher than gauge to allow any air in the system to rise and escape through bleed
off port.
4) Pump until the returns have no air and tighten up the bleed screw.
5) Pump some more fluid to get a one inch load gap.
6) Open the bleed screw and bleed back the load gap to 3/8 ins if using 50' of hose (1/2
ins if using 100' of hose).
7) Remove the pump and install the filler plug.
8) Check the correct reading of the gauge against a tensiometer or another weight
indicator.

CAUTION: Do not crush or cut the hose.

NOTE: Before picking up any weight across the load cell, the indicator should be
reset to zero.

8.6  Expro North Sea Ltd.

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8.4 MEASURING WHEEL
The purpose of the measuring wheel is to indicate accurately the length of wire passing
through it. It is set to zero with the tool at the wellhead, and therefore measures the depth of
the tool in the well.
The main component of the counter is an accurately machined grooved sheave around
which the wireline is normally wrapped once. Contact of the wireline with this measuring
wheel is maintained by the tension in the wireline and by two adjustable pressure wheels
machined to fit into the groove of the measuring wheel. The wheel is attached, either
directly to the axis of a digital meter (odometer) or by means of a flexible drive, permitting
location of the meter on the panel inside the cabin of the wireline unit.
For braided lines, straight line type measuring devices, such as those manufactured by
Mathey, Bowen, Gearhardt Owen and Otis are utilised. Alternatively, the measuring wheel
on the Halliburton type head can be changed and the 3/16 ins line run straight through the
head and not wrapped around the wheel.
Care should be taken to ensure that the correct path for the line round the measuring wheels
is selected to avoid reverse bending the wire.
The measuring device is normally mounted on moveable supports so that it can move
laterally, guided by the operator as the wire is spooled onto or from the drum. This is
controlled with a handwheel inside the cab through a spindle and chain arrangement.
A measuring wheel exists for each wire diameter and may be calibrated in feet or meters.
When changing the diameters of wire it is only necessary to change the wheel and pressure
wheels which are supplied in matched sets.
Prior to threading the wire through the counter, check that the counter wheel is free to
rotate and that the odometer is recording - this is especially important when there is a
flexible connection to the odometer in cab. Also check for wear in the counter rim and
pressure wheels.
Quick check for depth meter (counter): 8" wheel - 2 ft = 1 revolution
16" wheel - 4 ft = 1 revolution

Figure 8.3 – Halliburton ‘K’ Measuring Wheel

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Wireline Module 1
8.5 CAUSES FOR DEPTH DISCREPANCIES
There are many factors that can limit the linear accuracy of slickline measurement in the
tubing bore. With conventional measuring devices, the primary factors that affect true
measurement of a slickline are elastic stretch, temperature, buoyancy, drag, lift, and out-of-
tolerance measuring wheels. To further complicate matters, slickline varies in size and
material. The most commonly used slicklines are .092-, .108-, and .125-inch diameter
wires. The materials range from mild steel to alloy steels.
Elastic stretch for a slickline is a function of line tension and the modulus of elasticity of
the wire. The elastic stretch coefficients for the various wire sizes can usually be obtained
from the wire manufacturer but are, at best, an average; testing can reveal more accurate
coefficients. It is important to understand that line tension is not incorporated into the
depth measurements in conventional slickline measuring systems. Line tension is
measured using a hydraulic-type load sensor instead of an electronic strain gauge. The
hydraulic-type load sensors are calibrated to specific rig-up angles, usually 90 degrees,
since the load cell is placed in the lower sheave and will give inaccurate line tensions if the
included rig-up angle does not match the calibration.
Length measurements may be increased by out of tolerance measuring wheel diameters
resulting from wear or decreased because of debris build-up on the wheel surface. Changes
in measuring wheel diameters can result from large variations in ambient temperature
between the temperature at which the measuring wheel was manufactured or calibrated and
the temperature at which it operates. Temperature differences also affect wire length as it
is lowered into the well. Unless wellbore temperature/measurement variations are input
into depth corrections, this cause of variation is difficult to adjust.
The last factors affecting true wire length or tool depth are buoyancy and drag or lift, which
are a function of fluid viscosity, wellbore geometry, flowing conditions of the well, line
speed, etc. For all practical purposes, these factors are inherently measured as tension on
the surface. Extensive testing to determine compensation for wire-measurement changes or
dynamic tool depth because of these factors would be impractical for slickline applications
at this time.
Although these factors may not result in significant changes at shallow depths, they can
produce large discrepancies at deeper depths. Elastic stretch for .108-inch wire suspended
in a column of water accounts for the largest change in wire length at 12.5 feet in 10,000
feet. The temperature affects to the wire and measuring wheel were based on a 50°F
change at 50°F temperature change can result in a 3.92 ft change in 10,000 feet. The lack
of tolerance on the 4 foot circumference measuring wheel was based on a .001-inch change
to the measuring diameter, which caused a 0.65 foot change in 10,000 feet.
The load cell angle adjustment was shown to illustrate the change in depth if tension was
input incorrectly.
The 15° change in the included rig-up angle resulted in a 11/2 foot change in 10,000 feet. A
combination of any of these factors can create even greater linear inaccuracy.

8.8  Expro North Sea Ltd.

Wireline Module 1
8.5.1 Wireline Angle Correction Factors
The load registered on the weight indicator of the wireline unit does not indicate the total
load exerted on the line.
If the angle between the wireline entering and exiting the hay pulley is 90° then the reading
on the weight indicator is correct; see Figure 8.4. If the angle between the wireline
entering and exiting the hay pulley is less than 90° then the reading on the weight indicator
is higher than the actual load on the line. Refer to example 1.
If the angle between the line entering and exiting the hay pulley is more than 90 then the
reading on the weight indicator is lower than the actual load on the line. Example 2
Using the tables provided, the actual (resultant) load on the line can be calculated prior to
wireline operations. (Refer to examples 1 and 2)

Figure 8.4 - Martin Decker Weight Indicator 27

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Wireline Module 1
Example 1
Angle below 90O then WT indicator dial
reads higher than actual resultant.
e.g. Angle between entry and exit line =
70O
WT indicator reads 1000 lbs.
= 1000 ÷ 1.63830 (constant for 70O
from Table 8.1) x 1.41422 (constant for
90O from Table 8.1)
= 1000 ÷ 1.63830
= 610.3888 x 1.41422
= 863 lbs at 70O
Angle above 90O then weight indicator
dial reads lower than actual resultant.
Example 2
e.g. Angle between entry and exit line =
110O
WT indicator reads 811 lbs.
= 811 ÷ 1.14716 (constant for 110o
from Table 8.1) x 1.41422 (constant for
90O from Table 8.1)
= 811 lbs ÷ 1.14716
= 706.963. x 1.41422 = WT indicator
reads 811 lbs when resultant is 1000 lbs at
110O

Figure 8.5 – Examples

To interpolate odd number angles not shown on the following chart calculate according to
above formulae the resultant of the angle one degree less and one degree more than the
angle desired and split the difference. (Figures provided by Martin Decker, Aberdeen).

8.10  Expro North Sea Ltd.

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Included Line By Resultant Included Line By Resultant

Angle Of Load Constant Angle Of Load Constant
0 2.00000 92 1.38932
2 1.99970 94 1.36400
4 1.99878 96 1.33826
6 Multiply 1.99726 98 Multiply 1.31212 To Get
8 Line 1.99512 To Get 100 Line 1.28558 Resultant
10 Load 1.99238 Resultant 102 Load 1.25864
12 By 1.98904 104 By 1.23132
14 1.98510 106 1.20362
16 1.98054 108 1.17556
18 1.97538 110 1.14716
20 1.96962 112 1.11838
22 1.96326 114 1.08928
24 1.95630 116 1.05984
26 1.94874 118 1.03008
28 1.94058 120 1.00000
30 1.93186 122 0.96962
32 1.92252 124 0.93894
34 1.91260 126 0.90798
36 1.90212 128 0.87674
38 Multiply 1.89104 130 Multiply 0.84524
40 Line 1.87938 To Get 132 Line 0.81348 To Get
42 Load 1.86716 Resultant 134 Load 0.78146 Resultant
44 By 1.85436 136 By 0.74922
46 1.84100 138 0.71674
48 1.82708 140 0.68404
50 1.81262 142 0.65114
52 1.79758 144 0.61804
54 1.78202 146 0.58474
56 1.76590 148 0.55128
58 1.74924 150 0.51764
60 1.73206 152 0.48384
62 1.71434 154 0.44990
64 1.69610 156 0.41582
66 1.67734 158 0.38162
68 1.65808 160 0.34730
70 1.63830 162 0.31286
72 1.61804 164 0.27834
74 1.59726 166 0.24374
76 Multiply 1.57602 168 Multiply 0.20906
78 Line 1.55430 To Get 170 Line 0.17430 To Get
80 Load 1.53208 Resultant 172 Load 0.13952 Resultant
82 By 1.50942 174 By 0.10468
84 1.48626 176 0.06980
86 1.46270 178 0.03490
88 1.43868 180 0.00000
90 1.41422
Table 8.1 – Wireline Angle Correction Factors

 Expro North Sea Ltd. 1999 8.11

Wireline Module 1
8.6 WIRELINE CLAMP
The clamp is used to hold the wire while raising or lowering the lubricator and can be
utilised during fishing operations.
Clamps must be kept clean and dry to allow maximum grip on the wire.
The clamp is employed when it is necessary to clamp the wire and to hold the toolstring in
position, the tension from the unit to be slackened off during rigging up/down or on
operations where the tools are to be left in the well. It is also used in fishing operations to
engage a wireline which has parted above the BOP or stuffing box.
The clamp has grooves in the clamping jaws which grip the wire without crushing it,
assisted by a spring. It is usually attached to the lubricator by a clamp which is bolted
around the base of the bottom section of lubricator.
Care must be taken when placing the clamp on the line not to kink the wire. This can result
in a weak point or cause the line to stick in the stuffing box.

Figure 8.6 - Wireline Clamp

8.12  Expro North Sea Ltd.

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 Expro North Sea Ltd. 1999 8.13

Wireline Module 1
9 POWER PACKS

9.1 ELECTRICAL
The power pack discussed in this section is the Zone 1, 75 HP, electric/hydraulic type. This
power pack is an all steel construction skid mounted unit with detachable crash frame. Four
lifting points are provided with a safe working load of 2 tons. The heavy duty frame is
fitted with removable protection side panels for easy access and maintenance.
Most operators use diesel power packs but electrical power packs are used in some areas.
Electrical power packs are required to be intrinsically safe (i.e. spark-proof) and can be
used in Zone 1 operations. Zone 1 is an area around the wellhead which is restricted to
intrinsically safe equipment.
Electrical power packs are simple to operate and maintain. However, care must be taken to
ensure that the power pack is connected to the correct power source. When the power pack
has been connected, the direction in which the motor is running must be checked.
Little maintenance is required on electrical power packs. The hydraulic oil and the suction
strainer must be checked regularly.

Operation and Maintenance

Electric power packs are very simple to operate. However, care must be taken to ensure
that the power pack is connected to the correct power source. When the power pack has
been connected, the direction in which the motor is running must be checked.

NOTE: Before starting the electric pump, the hydraulic system must be looped or
connected to the wireline unit.

ZONE 0 In which a flammable atmosphere is continuously present, or present for long

periods (more than 1,000 hrs per year).
ZONE 1 In which a flammable atmosphere is likely to occur in normal operation (about 10
to 1000 hrs per year).
ZONE 2 In which a flammable atmosphere is not likely to occur in normal operation and if
it occurs it will exist only for a short period (less than 10 hrs per year).
Table 9.1

NOTE: The power pack shall be positioned and only operated in areas
designated as safe, in accordance with IP “model code of safe practice in
the petroleum industry”.

 Expro North Sea Ltd. 1999 9.1

Wireline Module 1

Figure 9.1- Electrical Power Pack

9.2  Expro North Sea Ltd.

Wireline Module 1
9.2 DIESEL POWER PACKS
Diesel engines are used because they are reliable. They can be made to function more
safely in hydrocarbon hazardous areas (no spark plugs, contact breakers, distributors etc.)
and the exhaust can be fitted with an efficient spark arrestor. Also diesel fuel is widely
available offshore, whereas petrol is normally not allowed. In the unlikely event of engine
problems, the following fault finding tree should lead you quickly to the fault. Diesels are
simple, they require only fuel and compression to operate.

Figure 9.2 - Diesel Power Pack

All units have safety systems fitted to the diesel engines which limits surface temperature
to below 200°C. (In the event of high exhaust or water temperature, automatic shutdown
will occur.) Overspeed shutdown is also used to prevent over-revving. The engines also
breathe through a special flame trap.

 Expro North Sea Ltd. 1999 9.3

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9.2.1 FAULT FINDING CHART
Fault Possible Cause
Low crank speed 1,2,3,4
Will not start 5,6,7,8,9,10,12,13,14,15,16,17,18,19,20,22,31,32,33
Difficult starting 5,7,8,9,10,11,12,13,14,15,16,18,19,20,21,22,24,29,31,32,33
Lack of power 8,9,10,11,12,13,14,18,19,20,21,22,23,24,25,26,27,31,32,33,60
Misfiring 8,9,10,12,13,14,16,18,19,20,25,26,28,29,30,32
Excessive fuel consumption 11,13,14,16,18,19,20,22,23,24,25,27,28,29,31,32,33,60
Black exhaust 11,13,14,16,18,19,20,22,24,25,27,28,29,31,32,33
Blue/white exhaust 4,16,18,19,20,25,27,31,33,34,35,45,56
Low oil pressure 4,36,37,38,39,40,42,43,44,58
Knocking 9,14,16,18,19,22,26,28,29,31,33,35,36,45,46,59
Erratic running 7,8,9,10,11,12,13,14,16,20,21,23,26,28,29,30,33,35,45,59
Vibration 13,14,20,23,25,26,29,30,33,45,47,48,49
High oil pressure 4,38,41
Overheating 11,13,14,16,18,19,24,25,45,50,51,52,53,54,57
Excessive crank case pressure 25,31,33,34,45,55
Poor compression 11,19,25,28,29,31,32,33,34,46,59
Starts and stops 10,11,12

Key To Fault Finding

9.4  Expro North Sea Ltd.

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10 WELL CONTROL AND B.O.P. PUMPS

10.1 SINGLE WELL CONTROL PANEL

When conducting well servicing operations in a well, it is a necessary safety precaution to
lock out any pneumatically or hydraulically activated valves and isolate them from the
platform control system.
This has meant the introduction of a mobile well control panel which effectively duplicates
the platform failsafe control system functionally for an individual well, but it is operated
manually. The well control panel is also provided with an emergency shutdown system,
enabling the UMV and DHSV to be closed instantly in an emergency situation.
An overview of the panel is given in Figure 10.1. It consists essentially of a control panel
section comprising of two reservoirs which feed three pneumatically operated Haskel
pumps. These provide a high pressure hydraulic supply for three functions:
1) UMV control – direct hydraulic (fluid depending on location).
2) DHSV control – direct hydraulic (fluid depending on location).
3) Wireline BOP stuffing box control – direct hydraulic (hydraulic oil).

A separate hand pump system is incorporate to enable the operation of a hydraulic stuffing
box system test line.
An additional facility is provided to allow the hook-up of an independent inhibitor supply
using the spare hose and reel.
The hydraulic supply hoses are wound onto four reels mounted beneath the control panel
section.
The low air supply/hydraulic pressure warning system is incorporated into the panel. The
warning system monitors DHSV pressure, UMV pressure and the air supply pressure. If
any of the aforementioned pressures fall below a pre-set level, an air horn sounds to warn
the operator, air supply should be taken from plant air not rig air as this can be lost at times,
such as water injection shut-down.

10.2 OPERATING PROCEDURES

10.2.1 Pre-Operational Function Checks
The functional checks prior to the operation of the panel are detailed below:
1) Locate the panel remotely from the wellhead in such a position that it may be
operated quickly and easily in an emergency, without compromising any route of
escape from the area. Recommended positions are:
• Beside the wireline winch unit, for operation on the skid deck.
• At bottom of Vee Door, for operations using rig.

2) Connect a dedicated air supply to the panel from plant air only.

 Expro North Sea Ltd. 1999 10.1

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3) Before connecting the panel hoses to the wellhead and BOP’s, the following function
checks should be performed.
• Pressure test the open and close BOP lines to 3,000psig.
• Pressurise the accumulative system, then close the accumulator valve. Utilising
the enclosed pressure, check for leaks.
• Check that the emergency shutdown (ESD) facility instantaneously dumps both
UMV and DHSV pressures. Reset by closing the ESD valve.
• Pressure test the stuffing box line to a maximum working pressure of
5,000psig.
• Check that the alarm air tank is sufficiently charged (>1,000psi) and function
test the alarm system on each of its separate operating criteria i.e. loss of air
supply. DHSV supply pressure decreasing and UMV supply pressure
decreasing.
• Check that the hydraulic fluid reservoir is filled above the minimum level.

4) Ensure that operations have disconnected the hard piping to the UMV. Make up
Parker Hannifan (or similar) connection to the open port on the actuator body and
connect up the UMV control hose to the actuator.
5) Ensure that operations have isolated the DHSV and main control panel from the
DHSV manifold on the tree flange. Make up Parker Hannifan (or similar) fitting to
this manifold and connect up to the DHSV control hose.
6) Prior to rig-up connect up to the BOP hoses and function test the rams by closing and
re-opening once.

NOTE: The open and close functions on the BOP should have male and female
quick-connect coupling halves respectfully, to prevent connection of the
functions the wrong way round.

10.2.2 Routine Operating Procedures

Throughout this part of the job the well will be under the control of the well service
supervisor who will operate or delegate operation of the panel as required. However, all
wireline personnel should be familiar with its operation, particularly its use in an
emergency situation.
During the entire period when the UMV and the DHSV are locked out from the platform
control system, two persons fully conversant with the operation of the panel must be
available at the wellsite.

10.2  Expro North Sea Ltd.

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The panel should be operated in accordance with the procedures detailed below:
1) As soon as the well has been handed over and prior to pressure control equipment
rig-up the Well Services Supervisor should take control of the well as follows:
• Remove the burst disc fitting from the actuator assembly (180° from control
pressure outlet) and insert 3/8in. NPT plug.
• Switch on the alarm system whenever a valve is open.

2) Once the pressure control equipment has been rigged and the BOP hoses connected
up to the BOP, turn the BOP control lever to the off (block) position. Turn on the
BOP pump and adjust the discharge pressure against this closed valve to suit the BOP
in use. No pressure will be applied to the BOP until the lever is switched to either the
open or the closed position.
3) During the wireline job, both UMV and DHSV pumps should be left in the on
position with the pressure regulated to maintain 3,000psig and 5,000psig
respectively. Regularly monitor for loss of pressure and pump stroking
4) The BOP pump should also be left in the on position, with the BOP operating
pressure preset using the pump regulator. The BOP control lever should be left in the
off position during normal operations.
5) If air supply pressure is lost, the pumps may be operated by hand levers, if required
to maintain pressure.
6) On completion of the job, control of the well should be returned to the platform
control system, with the DHSV left in the open position. The operations shift
supervisor should be informed via the CCR that the well has reverted to platform
control through the handover certificate system.

 Expro North Sea Ltd. 1999 10.3

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Figure 10.1 – Well Control Panel

10.4  Expro North Sea Ltd.

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Figure 10.2 – Well Control Panel Unit

 Expro North Sea Ltd. 1999 10.5

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10.6  Expro North Sea Ltd.

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11 GENERAL TOOLSTRING

The "Tool-string" is the name given to

any assembly of equipment run in the
well to perform some type of operation.
In wireline work, the string is run,
manipulated and retrieved by the
upward or downward movement of the
wire which is itself raised and lowered
by a winch at the surface.
The tool-string is made up of a number
of basic components with various other
service tools attached according to the
type of operation undertaken.
There are many different operations
and many different conditions to be
satisfied in each operation, so that the
number and type of service tools
available is very large, although some
tools are used far more frequently than
others. The precise configuration of
tool-string will be contingent on factors
such as job type, access, hole deviation,
depth, pressure, completion type, log
history and so on.

Figure 11.1 - Wireline Toolstring

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11.1 PRIMARY EQUIPMENT
11.1.1 Rope Sockets
The rope socket provides the means of attaching the wireline to the tool-string.

Pear Drop Socket

For 0.108 ins. and 0.125 ins. wireline the most commonly used rope socket is the pear drop
socket. This socket is easy to make up and little experience is necessary to "tie the knot"
reliably.
The principle of operation is that the wire, wrapped round a groove in the pear drop, is
wedged in a taper between the pear drop and the mating sleeve. This wedge action grips the
wire and is proportional to the tension applied to the wireline.
The benefits of this type of rope socket are that there are no sharp bends in the wire which
reduces its ultimate tensile strength, and is a simple and quick way to make the connection
to the wire.

Figure 11.2 - Pear Drop Type Rope Socket

11.2  Expro North Sea Ltd.

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11.1.2 Wireline Stem
Wireline stem or "sinker bar" is required as part of the wireline tool-string to increase the
weight.
A "rule of thumb" to determine the weight of solid steel stem is:
OD2 x 8/3 = Wt of stem in lb/ft.
Increase of stem weight increases the impact force delivered by the jars. The tool-string
should not be over-weighted as excessive mass dampens the "feel" and premature shearing
of shear pins can occur.
Flats for wrenches are provided and should be used. Do not grip the tool on the fishing
neck as this may damage the fishing neck shoulder.
All connections should be clean and dry. Do not lubricate tool-string threads as they could
unscrew downhole with extended periods of jarring.
The threads found on wireline tools are known as “sucker rod” thread. The three most
common sizes of thread are as follows.
• 15/16”
• 1 1/16”
• 1 9/16”

These sizes should be committed to memory.

Threads should be checked before rig up and after use. "Flaring" can occur on sinker bar
threads. This is indicated by the peaks of one or more threads being angled upwards rather
than at right angles to the stem. It is probably caused by a piece of stem being continually
used for heavy jarring. "Flared" threads do not grip uniformly with good/bad threads and
can back off very easily. Therefore, any pieces of stem with "flared" threads should be
replaced immediately.
The table below is a selection of some of the most common stem sizes and lengths that can
be used.

Size Thread Size Fishneck OD Max OD Length

1 ½” (1.5 in.) 15/16” Sucker Rod 1.375” 1.5” 2ft, 3ft, 5ft
1 7/8” (1.875 in.) 1 1/16” Sucker Rod 1.75” 1.875” 2ft, 3ft, 5ft
2 1/8” (2.125 in.) 1 1/16” Sucker Rod 1.75” 2.125” 2ft, 3ft, 5ft
2 ½” (2.5 in.) 1 9/16” Sucker Rod 2.313” 2.5” 2ft, 3ft, 5ft
1 7/8” Roller Stem 1 1/16” Sucker Rod 1.75” 2.125” Rollers 2ft, 3ft, 5ft
2 1/8” Roller Stem 1 1/16” Sucker Rod 1.75” 2.5” Rollers 2ft, 3ft, 5ft
2 ½” Roller Stem 1 9/16” Sucker Rod 2.313” 3.125” Rollers 2ft, 3ft, 5ft
Table 11.1

 Expro North Sea Ltd. 1999 11.3

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Figure 11.3 - Threaded Connections

11.4  Expro North Sea Ltd.

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11.1.3 Lead Stem
To provide greater weight for the same diameter and length lead-filled stems are available.
This stem has regular steel pin and box connections and a tubular steel outer barrel. The
inside is filled with lead to provide greater weight.
This stem is used primarily to run flow pressure and temperature survey tools to obtain
maximum weight with minimum cross-sectional area to protect against "floating" or being
blown up the hole by pressure surges.
Other high density, heavy weight stem which is available, includes: tungsten, uranium and
mallory (mercury alloy) filled stem.
DO NOT USE lead-filled stem for jarring as the lead will tend to creep downwards and
split the outer barrel.

Figure 11.4 - Lead Stem

 Expro North Sea Ltd. 1999 11.5

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11.1.4 Roller Stem
Roller Stem is used for work on deviated wells, or in wells with paraffin, asphaltine, etc. on
the tubing internal walls. It allows the stem to roll down the tubing wall, hence, cutting
down friction incurred when using regular stem.
NOTE: Nylon or Teflon rollers should be used in chrome and/or plastic coated tubing
(refer to Expro Operational Guidelines).

CAUTION: Rollers and axles should be inspected for wear before use. Tools to be
run should have a larger OD than the roller stem.

Figure 11.5 - Roller Stem

11.6  Expro North Sea Ltd.

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11.1.5 Jars
Jars are a principal component normally included in every toolstring. Their purpose is to
act as a downhole hammer and provide impact force to operate, set and retrieve downhole
equipment. Wireline alone cannot impart sufficient force due to its low breaking strength
and wellbore friction. Wireline is only used to convey and position the toolstring in the
wellbore.
Jars are activated by hand or winch movement of the wireline and it is essential that the
operator can recognise the precise opening and closing point of the jars on the wireline unit
weight indicator. If the jars are not being operated correctly or if the jar action is lost then
very little force can be exerted on the tools.
There are two main types of jar – Mechanical and Power
The normal mechanical jar is
• Spang jars (Long Stroke = 30” – Short Stroke 20”)
• Tubular jars
which have a mechanical action, and
• Spring jars
• Hydraulic Jars
which are upstroke jars only.
From the formula,
F = ma (Force = Mass x Acceleration)
it can be seen that increasing the impact force can be achieved by increasing the:
• Stem weight (Mass)
• Speed at impact (Acceleration/Kinetic Energy, Mechanical Jars only).

Jars would not normally be run in toolstrings that contain devices liable to damage by their
action, eg. pressure and temperature gauges, flowmeters, etc.

a) Spang Jars
Spang Jars; See Figure 11.6, are the most commonly used as they are mechanically simple,
require little maintenance and can be used to jar both up or down.
However, well debris can interfere with this action and their open construction could
possibly allow any wireline being fished to become entangled.
Jarring force in both directions is governed by stem weight and wire speed and to a lesser
extent by stroke length. However, the efficiency of jarring down is restricted by the
viscosity of the well fluid, the well deviation and the friction of the wire at the Stuffing
Box.
In deeper wells, long stroke jars can help give a more pronounced opening and closing
indication at surface. However, long stroke jars in large bore wells are prone to ‘scissoring’
caused by jarring down. In small bore tubing, the tubing walls prevent excessive buckling.
However, in large bore tubing, the elastic limit of the jar body may be exceeded, causing
permanent buckling and misalignment (‘scissoring’) of the upper and lower body parts.

 Expro North Sea Ltd. 1999 11.7

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Figure 11.6 - Spang Jars

11.8  Expro North Sea Ltd.

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b) Tubular Jars
Tubular Jars, See Figure 11.7, are commonly used when fishing for wireline or working
below tubing in the sump. Its moving components are for the most part enclosed inside a
housing, protecting it from entanglement with the wireline to be fished and other well
debris.
Tubular jars have screwed components, which are susceptible to backing off during
prolonged jarring. Also, the efficiency of jarring down may be decreased due to the
viscosity effects of the fluid displaced from inside the housing.

Figure 11.7 - Tubular Jars

 Expro North Sea Ltd. 1999 11.9

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c) Spring Jars
Spring Jars, See Figure 11.8, are used in situations where Spang Jars have been, or are
likely to be unsuccessful. This can be, for example, in deviated wells when wire speed is
insufficient or, in general, when more jarring force is required.

Figure 11.8 - Spring Jars

11.10  Expro North Sea Ltd.

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They can be used to jar-up but, because of their construction, it is possible for debris to
enter and make them difficult to reset. They also require regular maintenance. They are
used in gas wells in preference to hydraulic jars since they are not dependent on elastomer
seals (this removes the risk of fluid entry). In general, they are more durable than
Hydraulic Jars as their construction is purely mechanical.
The impact force of spring jars is determined by the selection or adjustment of the spring or
release mechanism. This spring or release mechanism prevents any relative movement of
the two parts of the jar, until a predetermined wire pull is reached. The first section of
relative motion of the two parts is to overcome the spring or release mechanism tension.
This in turn allows the release mechanism to actuate, freeing the inner rod to move
upwards without restriction and induce the jarring action.
If a Spring Jar malfunctions, it is not normally detrimental to the function of the rest of the
toolstring. If unable to release, it acts as a rigid section of toolstring. If unable to close, it
acts as an additional Spang Jar.

d) Hydraulic Jars
Hydraulic Jars, See Figure 11.9, are used in similar circumstances to spring jars ie. when
spang jars have been unsuccessful, or are likely to be unsuccessful.
The main advantage of the Hydraulic Jar is that the jarring force is adjustable, since it is
determined by the initial pull on the wire. In addition, this type of jar (in common with
spring jars) is more suited to extended jarring operations. This is because the wireline can
be run slower, since the impact force of these jars does not depend on the wire speed which
results in less wear and tear on the wire.
Hydraulic Jars can only be used to jar up and, because their construction includes many
elastomer seals, regular maintenance is required since well fluid and debris can enter the
hydraulic chamber.
In the presence of gas, the hydraulic oil can become contaminated. This alters its volume
and compressibility, reducing the jarring efficiency and can prevent the jar closing. In
addition, a ‘gassed-up’ hydraulic jar can seriously affect the jar-down action of the
mechanical jar in the string. Since the Hydraulic Jar is usually placed between the Stem and
the Mechanical Jar, it acts as a shock absorber, reducing the weight transmitted.
Upward pull on the wire pressurises the oil contained in the upper chamber. The piston is
designed not to form a good seal on the chamber bore and this will allow a slow controlled
flow of oil past it. The piston will travel upwards slowly until it encounters a wider bore
section of the chamber. At this point there is no longer significant resistance to the oil
flowing past the piston which will then move rapidly upwards to produce the jarring action.
To speed up the resetting action (closing), the piston contains a one-way check valve which
opens as the piston moves down.

NOTE: When rigging up or down heavy toolstrings, the hydraulic jars can be
opened under toolstring weight.

NOTE: Both spring and hydraulic jars should be fully closed prior to laying
down the toolstring to avoid bending or damaging the jar rod.

 Expro North Sea Ltd. 1999 11.11

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Figure 11.9 - Hydraulic Jars

11.12  Expro North Sea Ltd.

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11.1.6 Stretch Simulators/Accelerators
Stretch Simulators or Accelerators; see Figure 11.10, are installed in the Toolstring
immediately below the rope socket when Spring/Hydraulic Jars are to be used at shallow
depths. The spring replaces the ‘stretch’ of the wireline, which exists when jarring up. It
reduces the shock loading at the Rope Socket and causes the stem to ‘accelerate’ faster
when the Spring/ Hydraulic jars go off. This creates a more effective impact.
The device works by the wireline pulling on the top section while the bottom section is
held by the pulling tool. The internal spring is compressed and as the jar below fires, this
spring expands which in turn accelerates the toolstring giving more impact. This limits the
loading on the wireline. In theory it would be a good practice to use this device all the time
- but it makes the toolstring assembly complicated.

CAUTION: The assembly should be thoroughly checked prior to running, i.e. end-
subs tight, proper freedom of movement, spring in good condition.

NOTE: The accelerator must be matched with the correct vendor’s power jar.

 Expro North Sea Ltd. 1999 11.13

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Figure 11.10 - Wire Stretch Simulators

11.14  Expro North Sea Ltd.

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11.2 TOOLSTRING ACCESSORIES
There are many types of quick-lock connectors on the market, the following sections
describe the most common.

11.2.1 Quick-Lock System (Petroline)

Quick-Lock systems toolstrings may be used instead of (or in conjunction with) the
threaded type. The Quick Lock System, See Figure 11.11, is built onto the whole range of
toolstring equipment. There is no need for wrenches when making up this system. The
male half is mated to the female half, then rotated 90°. A spring loaded locking slip
engages a slot and locks the assembly in place. To release the locking device it is
mechanically lifted by means of a cut away window in the stem body.
This system is faster and easier to make up than the threaded type. It is stronger and will
not accidentally back off since it does not incorporate threads.
The advantage of using a Quick-Lock connector is that no wrench marks (and hence no
burrs) are induced on equipment (cutting down wear and hand injuries.)

Figure 11.11 - Petroline Quick-Lock System

 Expro North Sea Ltd. 1999 11.15

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Figure 11.12 – Trinity Locking System

11.16  Expro North Sea Ltd.

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11.2.2 Trinity Quick-Lock System
The most striking feature of the trinity quicklock is its triangular shape. Like the Petroline
quicklock its easy to make-up and adds strength by evenly distributing load round the
circumference of the connection. In addition to this the connection employs a support
shoulder to absorb side impacts and strengthens the female connection with the support
below the bottom lug. The locking and release mechanism is by way of a trigger mounted
in the female which unlike Petroline quicklock system is operated by hand and does not
require the use of any additional implements to release. It is also available as crossovers or
integral parts of toolstring components.

 Expro North Sea Ltd. 1999 11.17

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11.2.3 Knuckle Joints
Knuckle joints are included in the wireline tool-string to offer a degree of lateral flexibility.
They incorporate a ball joint assembly allowing rotation and some angulation.
During wireline operation in deviated wells, lengthy tool-strings without knuckle joints
may be forced to bend during running to follow the angles of the tubing. This causes
friction and up/down mobility can be seriously impaired. They are also used during fishing
operations to give flexibility between fishing tool and jars, and so aid latching.
Extended periods of jarring can damage the knuckle joint hence their use in tool-strings
should be kept to a minimum. The ball joints, threads, and any pins should be thoroughly
inspected prior to use.

Figure 11.13 - Knuckle Joints

11.18  Expro North Sea Ltd.

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12 BASIC PULLING TOOLS

12.1 FISHING NECK IDENTIFICATION / EXTERNAL / INTERNAL /

REACH
Pulling tools are for recovering and, to a lesser extent for running flow control assemblies
and other items of downhole equipment.
All downhole assemblies are equipped with standard fishing necks. To identify the
corresponding pulling tool, only the ID/OD and reach are required.
They are only used if a standard fishing neck is accessible. If not (eg. if a part of the tool
remains downhole) then a special tool (ie. an overshot) has to be used.
The pulling tool must be selected according to the size and type (internal or external) of the
lock mandrel (or other downhole devices) to be retrieved. This means that, at the time the
device is run, its size must be carefully measured and logged.
Pulling tools from different manufactures often have slightly differing detail design. For
this reason, they should be used with fishing necks from the same manufacturers if
possible. In practice, these small differences normally do not affect compatibility.

Figure 12.1 – Fishing Neck Compatibility

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Two types of fishing neck exist - internal and external. External fishing necks are used
generally on toolstrings and running and pulling tools.
The advantage of internal fishing necks is that they have larger flow areas and for this
reason are often used with flow control assemblies.
Both downhole assemblies and pulling tools may be set or sheared up or down. Any
combination is possible depending on the operation to be performed and the equipment
itself.
A shear-up pulling tool might be selected in preference if there is a potential difficulty
releasing by shearing down, e.g. debris around fishing neck, or a toolstring in a ball of wire
to be fished which moves down but not up.
A shear-down pulling tool might be selected in preference for extended periods of upward
jarring, to remove the risk of premature shearing off.
The pulling tool is fitted immediately below the spang jar, and the assembled tool is then
run to a depth predetermined by the location of the device to be retrieved. Where
necessary, a knuckle joint can be fitted between the pulling tool and the spang jar to assist
in the latching operation.
Therefore the operator must be able to immediately identify a tool's shear direction.
The shear direction and the outcome of running any pulling tool in the hole must be given
careful consideration at the planning stage of the job.

Tool Type Shear Direction

Otis ‘S' Series Down
Otis ‘R’ Series Up
Camco ‘JD’ Series Down
Camco ‘JU’ Series Up
Otis ‘GS’ Series Down
Otis 'GR’ Series Up
Table 12.1 - Shear Direction Chart

12.1.1 Selection of Shear Direction

It is essential that the operator selects a tool which shears in the direction opposite to which
jarring is required to achieve movement downhole, i.e. if a jar down action is required to
unlock a lock mandrel a jar up to shear tool must be used.

NOTE: In some cases this rule may not apply.

12.2  Expro North Sea Ltd.

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Figure 12.2 - General Operation of ‘SB’ Pulling Tool

 Expro North Sea Ltd. 1999 12.3

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12.2 EXTERNAL BASIC PULLING TOOLS
12.2.1 Otis ‘S’ Series Pulling tools (Shear down to release)
The type ‘S’ series of pulling tool is designed to engage with external fishing necks e.g.
rope sockets, stems, equalising prongs, test tools and to shear and release by downward jar
action. Three types of ‘S’ series tools are used and differ only by their core length, which is
selected to give a desired reach:
Type ‘SB’ Long core/short reach
Type ‘SS’ Intermediate core/Intermediate reach
Type ‘SJ’ Short core/long reach
All other parts of the tools are identical and completely interchangeable.
Type ‘SM’ Intermediate core / Intermediate reach. Used mainly to pull gas lift valves.

Figure 12.3 - ‘S’ Core Length and Corresponding Applications

12.4  Expro North Sea Ltd.

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a) Operational
On reaching the working depth, the weight of the tool-string bears down on the device to
be pulled and, if necessary, is backed up by a light downward jar.

NOTE: Downward jarring at this stage should be kept to a minimum to avoid

premature shearing.

Once latched on, pulling operations can begin.

Due to the design of the tool, the downward force produced by the jarring action is exerted
through the pulling tool cylinder (skirt) and, in turn, through the shear pin. The core must
therefore remain stationary and the cylinder must move downwards in relationship to the
core, in order to shear the pin. The tool cannot be sheared if the cylinder is unable to move
downwards because it is resting on the fish or devices to be released.
A feature of the ‘S’ series pulling tool is its ability to sustain upwards jarring without
releasing. In certain circumstances the tool can be used in running operations.
Another version or type of ‘S’ series pulling tool is the Type ‘SM’. This is a special
purpose tool designed primarily to retrieve certain side pocket gas lift latches. Although it
is a shear down to release tool of similar design to the Types ‘SB’ and ‘SS’, various
dimensions are different and components are not usually interchangeable.

b) Operational Check
It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be redressed before storing.

12.2.2 Otis ‘R’ Series Pulling Tools (Jar up to release)

Figure 12.4 is designed to engage with external fishing necks, e.g. rope sockets, stems,
equalising prongs, test tools and to shear and release by upward jar action. Three types of
‘R’ series tools are used and differ only by their core length; see Figure 12.4, which is
selected to give a desired reach:
• Type ‘RB’ - long core/short reach
• Type ‘RS’ - intermediate core/intermediate reach
• Type ‘RJ’ - short core/long reach.

(All other parts of each type of tool are identical and completely interchangeable.)
On reaching the working depth, the weight of the toolstring bears down on the device to be
pulled and, if necessary, is backed up by light downward jarring.
Once latched, pulling operations can begin.

 Expro North Sea Ltd. 1999 12.5

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If the pulling operation is prevented by, for example, the build up of debris, scale or
differential pressure, the shear pin will shear and so unlatch the dogs from the fishing neck.
The pulling tool can now be retrieved, redressed or changed for another type.

NOTE: When jarring up with ‘R’ tools, large forces can be imparted to the shear
pin. For this reason, these tools are generally fitted with larger shear pins
than those fitted to equivalent shear down tools. Despite this, as the shear
pin takes the full load of the force imparted by the jar, it can sometimes
shear before the pulling operation is accomplished.

Two features of the ‘R’ Series pulling tool are its ability to sustain downwards jarring
without releasing and it is not dependent on the core bottoming out to achieve shearing.
In certain circumstances, the tool can be used in running operations.
It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be cleaned and redressed before storing.
The ‘R’ Pulling Tool is attached to a standard toolstring and lowered into the well. Upon
contact with the sub-surface device, the lower portion of the cylinder passes over the
fishing neck; the dogs are pushed outward, the force of the dog spring then makes the dogs
spring inward to engage the fish neck. Upward impact of the jars is used to pull the sub-
surface device from the well.
The shear pin should withstand considerable jarring before shearing. When the pin shears,
the cylinder spring acts between the cover and the cylinder and moves the core up in the
cylinder. This moves the dogs upward against the force of the dog spring. As the dogs
move upward, their tapered upper ends move into the cylinder, forcing the dogs inward
thereby pushing the lower ends of the dogs outward. This causes the dogs to release their
grip on the fish neck.

12.6  Expro North Sea Ltd.

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Figure 12.4 - Otis Type ‘R’ Pulling Tool

 Expro North Sea Ltd. 1999 12.7

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12.2.3 Camco ‘JD’ Series Pulling Tools (Jar down for release)
The type ‘JD’ series Pulling Tool; see Figure 12.5, is designed to engage with external fish
necks, eg. rope sockets, stems, equalising prongs, test tools and to shear and release by
downward jar action. Three types of ‘JD’ series tools are used and differ only by their core
length, which is selected to give the desired reach:
• Type ‘JDC’ - long core/short reach
• Type ‘JDS’ - intermediate core/intermediate reach
• Type ‘JDL’ - short core/long reach.

(All other parts of each type of tool are identical and completely interchangeable.)
On reaching the working depth, the weight of the toolstring bears down on the device to be
pulled and, if necessary, is backed-up by light downward jarring.

NOTE: Downward jarring at this stage should be kept to a minimum to avoid

premature shearing.

Once latched on, pulling operations can begin.

Due to the design of the tool, the downward force produced by the jarring action is exerted
through the pulling tool cylinder (skirt) and, in turn, through the shear pin. The core must,
therefore, remain stationary and the cylinder must move downward in relation to the core
in order to shear the pin. The tool cannot be sheared if the cylinder is resting on the fish or
device to be released.
A feature of the ‘JD’ pulling tool is its ability to sustain upwards jarring without releasing.
In certain circumstances, the tool can be used in running operations.
It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be cleaned and redressed before storing.

12.8  Expro North Sea Ltd.

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Figure 12.5 - Camco Type ‘JD’ Pulling Tool

 Expro North Sea Ltd. 1999 12.9

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12.2.4 ‘JU’ Series Pulling Tools (Jar up to release)
The type ‘JU’ Pulling Tool; see Figure 12.6, is designed to engage with external fishing
necks eg. rope sockets, stems, equalising prongs, test tools and to shear and release by
upward jar action. Three types of ‘JU’ Series tools are used and differ only by their core
length which is selected to give a desired reach:
• Type ‘JUC’ - Long core/short reach
• Type ‘JUS’ - Intermediate core/intermediate reach
• Type ‘JUL’ - Short core/long reach.

(All other parts of each type of tool are identical and completely interchangeable.)
On reaching the working depth, the weight of the toolstring bears down on the device to be
pulled and, if necessary, is backed up by light downward jarring.
Once latched on, pulling operations can begin.
If the pulling operation is prevented by, for example, the build up of debris, differential
pressure or scale, the shear pin will shear and so unlatch the dogs from the fishing neck.
The pulling tool can now be retrieved, redressed or changed for another type.

NOTE: When jarring up with ‘JU’ tools, the shear pin takes the full load of the
force imparted by the jar, it can sometimes shear before the pulling
operation is accomplished.

It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be redressed before storing.

12.10  Expro North Sea Ltd.

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Figure 12.6 - Camco Type ‘JU’ Pulling Tool

 Expro North Sea Ltd. 1999 12.11

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Figure 12.7 – Shear Pins

12.12  Expro North Sea Ltd.

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12.2.5 Otis "GS" Pulling Tool
The type "GS" pulling tool is designed to engage with internal fishing necks e.g. lock
mandrels and to shear and release by downward jar action.

Operation
On reaching the working depth, the weight of the tool-string bears down on the device to
be pulled and if necessary, is backed up by a light downward jar. On locating the device to
be pulled, the dogs of the "GS" automatically engage by their upward movement over the
tapered core. This allows the dogs to retract and enter the recessed pulling neck. Once in
the recess, a spring forces the dogs down over the taper and out into the lock mandrel fish
neck. As the fish neck has a restricted diameter, the dogs are securely locked in the mandrel
and upward jarring can commence.

NOTE: Downward jarring at this stage should be kept to a minimum to avoid

premature shearing.

Due to the design of the tool, the downward force produced by the jarring action, is exerted
through the pulling tool core and in turn through the shear pin. The skirt must, therefore,
remain stationary and the core must move downwards in relation to the skirt in order to
shear the pin. The tool cannot be sheared if the core is resting on debris etc. A feature of
the "GS" pulling tool is its ability to sustain upward jarring without releasing. In certain
circumstances, the tool can be used in running operations when fitted with an appropriate
prong.

Operational Checks
It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be redressed before storing. To release the pulling tool from the
lock mandrel; grasp the dog retainer with the thumb and forefinger and force it up to
compress the spring. This should lift the dogs enough to allow them to retract against the
small outside diameter of the core. Remove the mandrel from the pulling tool

 Expro North Sea Ltd. 1999 12.13

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Disassembly Procedure
1) Place the "GS" pulling tool in a vice, gripping the flats on either side of the core
bottom.
2) Rotate the shear pin retainer sleeve until the shear pin ends are exposed. Carefully
drive out the shear pin.

NOTE: Bear in mind that the cylinder spring is under compression and will snap
the cylinder back to the fish neck shoulder upon pin removal.

3) Loosen the set screw in the fish neck and remove the fish neck from the core.
4) The remaining cylinder sub assembly can now slide off the upper end of the
core.

NOTE: At this point, the core can be changed without further disassembly of the
tool.

5) Insert the cylinder in a vice and remove the top sub which also retains the shear pin
sleeve.
6) Remove the cylinder spring from the inside of the cylinder top sub.
7) The cylinder spring retainer, dog spring, dog retainer and dog segments may now be
removed from the cylinder body.

12.14  Expro North Sea Ltd.

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Assembly Procedure
Prior to assembly, wash all parts thoroughly and lubricate all threads with good quality
thread lubricant.
1) Place the cylinder horizontally in the jaws of the vice with one window of the
cylinder facing up.
2) Slide the dog retainer through the threaded end of the cylinder and position it in the
dog retainer.
3) Insert one dog through the lower end of the cylinder and position it in the dog
retainer.
4) Reaching through the threaded end of the cylinder, rotate the dog retainer until the
next dog slot appears in the window of the cylinder. Insert the next dog as before, and
continue until all dogs are in place.
5) When all dogs are in place, move the dog retainer and the attached dogs all the way
down into the cylinder.
6) Install the dog spring over the spring retainer, and insert the spring retainer, and
insert the spring retainer (small end first) through the threaded end of the cylinder.
7) Insert the cylinder spring into the area under the threads of the top sub.
8) Make up the top sub and shear pin retainer sleeve into the cylinder and remove it
from the vice.
9) Grasp the flats on the lower end of the core in the vice with the core in the vertical
position.
10) Slide the cylinder assembly down over the core.
11) Make up the fish neck onto the core and tighten the connections.
12) Install the set screw.
13) Before using the tool, install the shear pin.

Re-pinning Procedure (Using "GU" Adapter)

1) Place the "GU" adapter in the vice.
2) Turn the shear pin retainer sleeve on the "GS" to expose the sheared parts of the shear
pin. On some types of "GS" the cylinder will have to be backed off to expose the
shear pin.
3) Turn the "GS" horizontally and using its own weight only, tap lightly on a bench or
vice. This should expel the broken parts of a shear pin;
4) Screw the fishing neck of the "GS" into the "GU" adapter. This action will overcome
the spring tension of the "GS" and align the shear pin holes.
5) Insert the new shear pin (this will drive out the remaining part of old pin) and cut it to
size.
6) Turn the shear pin retainer sleeve 90' to cover the shear pin.
7) Unscrew the "GS" from the "GU" adapter and remove the "GU" adapter from the
vice. (The "GS" is now ready for use).

 Expro North Sea Ltd. 1999 12.15

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Figure 12.8 – Otis ‘GS’ Pulling Tool

12.16  Expro North Sea Ltd.

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Figure 12.9 – Otis ‘GU’ Adapter

 Expro North Sea Ltd. 1999 12.17

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12.2.6 Otis "GR" Pulling Tool
The type "GR" pulling tool is basically a "GS" pulling tool converted by fitting an adapter
("GU" adapter – discussed later) to release and shear by upward jar action.

Operation
On reaching the working depth, the weight of the tool-string bears down on the device to
be pulled and, if necessary, is backed up by light downward jarring. On locating, the dogs
of the "GR" automatically engage as they move upwards over the tapered core. This allows
the dogs to retract and enter the recessed pulling neck. Once in the recess, a spring forces
the dogs down over the taper and out into the lock mandrel fish neck. As the fishneck has a
restricted diameter, the dogs are securely locked in the mandrel and upward jarring can
commence.
Due to the design of the tool, the upward force produced by the jarring action, is exerted
through the pulling tool skirt and, in turn, through the shear pin. The core must, therefore,
remain stationary and the skirt must move upwards in relationship to the core in order to
shear the pin.
Features of the "GR" tool:
Can sustain downwards jarring without releasing.
Can be sheared when movement of the core is restrained by debris in the lock mandrel i.e.
shearing only requires that the dogs are locked in the fish neck.

Operational Checks
It is recommended that the shear mechanism is tested prior to use. Following recovery from
the well, the tool should be redressed before storing.

12.18  Expro North Sea Ltd.

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Figure 12.10 – Otis ‘GR’ Pulling Tool

 Expro North Sea Ltd. 1999 12.19

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"GU" Adapter Assembly Onto "GS" Pulling Tool
(Assuming adapter shear pin is sheared)
1) Carefully drive the shear pin from the "GS" pulling tool, with consideration to the
compressed cylinder spring.
2) Remove the set screw in the core nut of the "GU" adapter via the port in the main
body, after screwing the core nut downwards to expose the set screw. The pin thus
exposed should be removed
3) The "GU" adapter fish neck should then slide off the core nut.
4) The "GU" adapter shear pin retainer band should be rotated, until the holes align with
and expose the shear pin pieces which should be driven out.
5) The adapter core nut should be tightened onto the "GS" pulling tool fish neck thread,
with the "GS" core held firmly in a vice on the flats of the core bottom.
6) The "GU" adapter fish neck should be lowered over the core nut to the adapter fish
neck.
7) The "GU" adapter pin should be installed through the slotted hole in the fish neck and
the socket head set screw installed to retain the pin. This action secures the adapter
core nut to the adapter fish neck.
8) Compress the "GS" tool cylinder spring until the shear pin holes in the adapter fish
neck and core nut align and install a shear pin.
9) Rotate the shear pin retainer band 90' to retain the pin. The retainer band may be
dimpled with a punch if it is a loose fit and then rotated offset.

"GU" Adapter Assembly Onto "GS" Pulling Tool

(Assuming shear pins are unsheared)
1) With "GS" pulling tool gripped in a vice on the flats of the core bottom, screw the
adapter onto the pulling tool fish neck and tighten with wrench.
2) Rotate pulling tool shear pin retainer and check that the shear pin is removed prior to
running the tool.

CAUTION: If a shear pin is left in the "GS" palling tool, as well as the "GU"
adapter, shear off in any direction will be impossible resulting in a
stack tool

NOTE: A "GU" adapter may be utilised to re-pin a "GS" pulling tool using the
above method in the absence of a spring compressor tool.

12.20  Expro North Sea Ltd.

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12.2.7 Otis "GU" Adapter
As described above in the "GR" pulling tool section, the "GU" adapter has the primary
function of converting a "GS" tool to a "GR" tool. The "GU"/"GS" assembly can then be
used in operations where release by upward jar action is required. Another use for this
adapter, though non-operational, is to assist in re-pinning the "GS" tool after shear. The
adapter, on uniting with the "GS" tool, pushes its skirt down to expose the damaged shear
pin for removal with a punch.

Disassembly Procedure
1) Grip the fish neck in a vice.
2) Rotate band until the shear pin is exposed and drive out the shear pin with a pin
punch.
3) Move the core nut downwards to the full downward travel position until the set screw
is visible through the port in the main body cylinder.
4) Remove the set screw from the port and drive out the pin thus exposed.
5) Remove the core nut.

Assembly Procedure
Assemble in reverse order from disassembly.

 Expro North Sea Ltd. 1999 12.21

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FISH NECK SIZES NOMINAL PULLING TOOLS

1 187" 1 1/2" PULLING TOOL
1.375" 2" PULLING TOOL
1.75" 2 1/2" PULLING TOOL
2.313" 3" PULLING TOOL
3.125" 4" PULLING TOOL
Table 12.2

The above table is a selection of fish neck sizes that are most commonly found and the
pulling tools which will latch the corresponding fish neck.

NOTE: Fishing neck profiles should never be used for breaking tools. Inspect
fishing neck profiles for burrs and wrench damage. While it is
inconceivable that wireline tools and equipment could be used without
sustaining some wear and/or damage, it is inexcusable to carry on using
them in a badly worn or damaged state.

12.2.8 Shear Stock Sizes/Shear Pins

The following chart is a guide to the most common shear stock sizes used in the North Sea
today. However some wireline tools use shear screws rather than conventional shear stock.

SHEAR STOCK SIZES

3/16"
1/4"
5/16"
3/8"

As a general rule the following should be remembered:

• Brass shear stock for setting or light jar action.
• Steel shear stock for pulling or heavy jar action.

This may not always apply and should only be used as a guide.

12.22  Expro North Sea Ltd.

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13 BASIC WIRELINE TOOLS

13.1 GAUGE CUTTER

It is good wireline practice to run a gauge cutter or similar drift before starting any
operation in a well, to check tubing ID and to tag the total depth, to locate the nipple ID
and No-Go's, to cut sand, scale, paraffin and other deposits from the tubing wall. It is also
used to determine the profile of a bridge by running successively smaller cutters and
plotting depth versus sizes to establish the shape of restriction.

a) Advantages
This tool has no moving parts, has a maintenance free sharp cutting edge requiring little
attention and, incorporates a fish neck.

b) Disadvantages
If smaller gauge rings are used in large casing/tubing ID's when attempting to clear
restrictions, scale/sand debris can fall on top of tool-string and affect the jar action.
Gauge cutters have no shear off facility.

Figure 13.1 - Gauge Cutter

 Expro North Sea Ltd. 1999 13.1

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13.2 LEAD IMPRESSION BLOCK
The lead impression block is filled with lead which extends below the bottom edge. The
lead is held in position by a roll pin or a hex-headed bolt. Either of these are installed prior
to pouring molten lead inside.

a) Advantages
Lead impression blocks are used to obtain an image of a wide range of equipment
downhole to be latched or fished, e.g. rope sockets (with or without wire), prongs, lock
mandrels and parted tubing.
They have no moving parts and incorporate a fishing facility.

b) Disadvantages
Lead impression blocks have no shear-off facility.
A false or double impression can occur at obstructions while running in hole (RIH) prior to
reaching the obstruction/tool to be fished, causing difficulty when interpreting the image
obtained.
Use one single downward stroke to make the impression.

Figure 13.2 - Lead Impression Block

13.2  Expro North Sea Ltd.

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13.3 BLIND BOX
The blind box is used when heavy downward jarring is required to dislodge a fish or push a
tool down the hole. It is flat on the bottom and hardened to reduce wear and damage.

a) Advantages
Blind boxes are available in a wide range of sizes and incorporate a fishing facility. They
require little maintenance as they have no moving parts.

b) Disadvantages
Blind boxes do not have a shear off facility and they can become entangled with wireline
when fishing and can damage the restriction to be jarred on.

Figure 13.3 - Blind Box

 Expro North Sea Ltd. 1999 13.3

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13.4 TUBING END LOCATOR
Tubing end locators are used to locate the end of the tubing when running the completion
as a cross reference check of the tubing tally. They are used also to correlate hold up depth
(HUD), or plugged back total depth (PBTD) accurately from the bottom of the tubing, the
depth of which is known from completion records.

WARNING: The tubing end locator body, finger length and minimum ID of the
tubing end needs to be checked to match the size of the tubing end in
which it is to be run. Also if there is a mis-run the finger may need to
be sheared to get back out of the well. (see Figure 13.4).

Figure 13.4 - Tubing End Locator

13.4  Expro North Sea Ltd.

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a) Advantages
Tubing end locators are also used to correlate pressure/temperature gauges, etc. and may
eliminate the use of more expensive correlating equipment.
They are available in a range of sizes, incorporate a fishing facility, and are quick and easy
to maintain.

b) Disadvantages
During pressure testing the tool-string position must be known and monitored as an
increase in pressure can move the tubing end locator up-hole hence shearing the pin.
Care must be taken when loading the tubing end locator into the lubricator to prevent
premature tripping.
When the tool is run and passes out of the tubing the spring loaded "finger" trips out to the
horizontal position. When pulled back, the bottom of the tubing is indicated by overpull.
After this has been done, a further quick pull into the tubing shears a brass pin and allows
the "finger" to collapse against the tool body, permitting the toolstring to be retrieved.

CAUTION: A gauge run is recommended before running the tubing end locator to
ensure that it will pass through the tubing. otherwise, a missrun would
entail pulling the tool with the "finger" in the running position, which
could lead to damage to the tubulars where the "finger" made contact
with them. when this happens the pivot pin will shear, dropping the
"finger" and spring downhole.

 Expro North Sea Ltd. 1999 13.5

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13.6  Expro North Sea Ltd.

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14 SAFETY AND AREAS OF RESPONSIBILITY

14.1 GENERAL SAFETY

14.1.1 Introduction
Whether onshore or offshore, there are many laws to enforce safety which place duties on
both employers and employees.
Very basically, the law requires that the employer must provide a safe place of work and all
necessary equipment required to do the job safely, whilst the employee must, in turn, work
safely, use all the protective equipment supplied and not do anything or omit to do anything
that could lead to an accident, with consequent injury or damage to equipment.

14.1.2 Wireline Safety (Refer to Expro Operational Guidelines)

The wireline unit must always be safely located and properly secured to prevent movement
when a load is supplied.
• The wireline unit must be a sufficient distance from the lubricator to enable the
operator to spool wire onto the drum without undue effort. This reduces
damage to the rollers and helps to even respooling.
• There must always be at least two wireline personnel present on site during
wireline operations.
• Wireline lubricators and BOP rams must be subjected to a pressure test and
functional test prior to wireline operations. (Discussed in Slickline Procedures)
• Before using power packs, ensure that the hoses are properly connected to the
correct fittings. For electrical power packs, ensure the motor turns in the
correct direction. The power pack should not be started until the relevant
permit has been issued.
• The lubricator must be long enough to accommodate the longest toolstring
which might be pulled from the well.
• The use of hay pulleys must be kept to a minimum and those in use must be in
direct line of sight of the operator.
• Barriers and warning signs must be posted. PA announcements must be made
as required to warn all non-essential personnel to stay clear of the area.
• Any hydraulic pumps used to actuate BOPs, the stuffing box etc, must be
situated at a location remote from the wellhead area.
• During the period that the wireline is in the hole, all valves in line with the
wellbore must be secured open by a fail-safe system. A responsible person
must supervise the remotely operated control system during wireline operations
at all times.
• Wireline personnel must be aware of all equipment that has moving parts,
including the wireline drum, moving wire, depth encoder wheel and hay
pulleys (particularly the load cell hay pulley) to ensure that clothing, loose
articles etc, do not become trapped while the line is in motion.

 Expro North Sea Ltd. 1999 14.1

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NOTE: Wireline winch must not be operated with safety guards removed or
damaged.

• During the period that the wireline is rigged up or in the hole, there must be no
crane lifting operations over, or in close vicinity to, the wireline.
• A wireline clamp must be applied whenever the wireline is left static for any
length of time or when work is to be carried out on surface equipment with the
wireline in the hole.
• When carrying out maintenance on devices which contain springs, the
following precautions must be taken:
1) Work must be properly secured (e.g. in a vice)
2) No person shall be in line with equipment while it is being dismantled
3) Extra care must be exercised when moving parts appear to be binding or
stuck.
• When wireline work is suspended or completed, the well must be left in a safe
condition. The site must also be left in a safe and tidy manner.

a) Lifting Equipment
All lifting equipment used on installations will be certified and a copy of the certificate will
be kept on board. Refer to Expro Operational Guidelines for further information

b) Pressure (Control Equipment)

All pressure control equipment, e.g. lubricator, BOPs, stuffing-box etc. must carry valid
certification and a copy of the certificate will be kept on board. Refer to Expro
Operational Guidelines for further information.

c) Wireline Work in an H2S Environment

Hydrogen Sulphide (H2S) occurs naturally from the decay of organic matter containing
sulphur and is to be found in varying quantities within some oil wells. H2S is a highly
flammable and toxic gas. It has a distinct smell of rotten eggs up to 20-30 ppm but as the
concentration increases the odour becomes sweetish and the gas diminishes the sense of
smell so that at 150 ppm, no smell is detectable. Therefore, smell is not a reliable guide to
its presence. Refer to Expro Operational Guidelines for further information.

14.2  Expro North Sea Ltd.

Wireline Module 1
Whenever wireline work is carried out on H2S wells, extreme care must be taken.
The following points in particular should be noted:
• A pre-work safety briefing must be held in which all departments concerned
should be involved, including, for example, Wireline, Safety, Drilling and
Medical.
• All persons involved in the work shall be conversant with H2S procedures for
recognition, escape, and first aid treatment.
• Barriers and warning notices must be erected and PA announcements made as
appropriate.
• A job site H2S monitor will be provided and personnel briefing in its use.
• The responsible person planning the work and organising the worksite must be
aware of wind direction and prevailing weather conditions throughout the
duration of the job.
• A sufficient number of BA sets must be readily available at the worksite.

 Expro North Sea Ltd. 1999 14.3

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14.2 WIRELINE OPERATIONAL GUIDELINES
14.2.1 Surface Operations
Introduction
For the purpose of Wireline Operations, safety awareness can be broken down into four
main areas:
• Planning
• Rig-up and Rig-down Operations
• Pressure Testing
• In-hole Operations.

The well files and programme should be studied, all information about depths of sub-
assemblies, previous toolstrings, tubing string and sub-assembly IDs should be noted.
Abnormal conditions, tight spots, sand fills, waxing problems, deviation and kick-off
points and position of any previous fish should be identified and highlighted.
Sub-assembly size and type should be noted and Supervisors and Service Personnel must
be familiar with the completion and wireline equipment, SSDs, positioning tools, shear
directions, etc. Tubing ends should be located and the size and depth of the rathole noted.
Complete all the necessary company documentation, obtain all Work Permits, Isolation
Permits, Wireline Intervention Permits etc.
Inspect the Certification Documentation for the Wireline BOP, Lubricator, and Stuffing
Box. Only recently tested and certified equipment should be used. Do not commence any
wireline work without a correctly detailed well schematic in the wireline unit.
The job briefing by the wireline supervisor should describe, in detail, the objectives, the
methods, and the safety requirements. All operatives should indicate that they have fully
understood the brief and that all questions have been answered.

14.2.2 Equipment Location and Layout

(Refer to Expro Operational Guidelines)
Figure 14.1 illustrates a typical surface wireline equipment layout from the Drill Floor to
the Pipe Deck. However, this layout will vary from location to location and equipment
requirements will differ, i.e. when equipment is moved from an offshore to a land location;
the requirement for a wireline mast, trucks and cranes all have to be considered.
Regardless of the equipment type/layout/location, all personnel must be conversant with
basic safety standards e.g. working dress code, cordoning off wireline areas, and the
erection of warning signs including those pertaining to hazardous zones, fire precautions
and clear access; such safety requirements are laid down in Company Policy. Personnel
must also be familiar with the appropriate emergency procedures.
Wireline units should be adequately anchored; even the heavier skid-mounted and truck-
mounted types should be securely anchored regardless of the operation being performed.

14.4  Expro North Sea Ltd.

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Wireline masts and lubricators should be guyed for stability and safety. Anchoring and
guying may require the use of chains, steel ropes, shackles, bulldog clips, steel bolts and
nuts, load binders ('come alongs', Tirfor winches) and, where no anchor points exist,
pickets and stakes. To ensure safe operation, these items should be included in sufficient
quantities in the back-up equipment to be dispatched to the work site and certified where
needed.

CAUTION: Large and heavy equipment is moved and lifted during rig-up and rig-
down and all personnel must use the correct equipment and remain
alert to avoid accidents. All non-essential personnel must be kept clear
of the area and new/trainee personnel assisting in the work must be
fully briefed on the operation before starting. All platform safety
regulations must be fully complied with, including work permit
procedures.

Figure 14.1 – Example of Equipment Location and Layout

 Expro North Sea Ltd. 1999 14.5

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14.2.3 Rig-Up/Rig-Down Considerations
The following list details the minimum safety requirements for Wireline Operations
regardless of the lifting system used:
• The wireline winch must be secured to the deck by certified slings
• The wireline crew are responsible for rigging up/down the wireline lubricators
and Chiksan Lines using only the wireline hoists. The wireline crew have no
responsibility for any other rigging
• Diesel powerpacks must be as far as possible from the lubricator. Operator
requires a Hot Work Permit (HWP)
• All hay pulleys must be in direct line of sight of the operator
• The lubricator should be long enough to accommodate the largest toolstring
which might be pulled from the well
• The correct BOPs are to be used, handles attached and hydraulic hoses
correctly fitted
• Barriers and warning signs to be in position
• All non-essential personnel are to clear the area
• BOPs are to be stroked to check operation
• Lubricator must have been recently pressure tested
• Remote failsafe control must be in operation
• All production valves to be checked for correct position by production staff.
All lubricator bleeding to closed drain system only
• Determine hay pulley angle to ensure that the correct line pull is obtained
• Ensure that accurate CITHP is available.

14.2.4 Pressure Testing and Pressurising Lubricators (Refer to Expro Operational

Guidelines)
In general, wireline lubricators will be subjected to the following pressure tests:
• Full workshop pressure testing; this is a test to verify the material strength. API
recommend 1.5 times the manufacturer's maximum working pressure
• On-site pressure testing; this is a hydrostatic test to maximum expected CITHP
+ 500 psi. to verify pressure integrity every time the equipment is rigged up
• Lubricators are tested to full test pressure in base workshops on a scheduled
basis depending on usage.

NOTE: Some oil companies require annual NDT testing of wireline lubricators,
BOPs, etc. A current NDT certificate has to be produced prior to
shipping.

14.6  Expro North Sea Ltd.

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In a workshop test, the lubricator sections are filled with water, sealed at each end with
either a male or female test cap, and installed in a test rig in a test cellar or similar protected
location. Pressure is then applied in stages until full test pressure is achieved (API specify
full working pressure plus 50% for all pressures up to and including 10,000 psi.); this is
held for a specified time before release. The date of the test and pressure applied are
stamped on a metal band or tag attached to the section, and the history card of the item
updated.

NOTE: The lubricator section itself must NOT be stamped; it must be stainless
steel banded.

Contractor supplied lubricators should be subjected to a full pressure test before use; these
tests should be recorded on a chart and witnessed by a company representative. This should
preferably be carried out in base workshops where full, safe, test facilities exist. In
addition, lubricators should be tested following installation on the wellhead; normally the
pressure will be the expected CITHP plus a safety margin (See Expro Operational
Guidelines). During this test, all non-essential personnel must be cleared from the area and
operator(s) implementing the test must be screened from the danger of flying debris should
the lubricator structure fail.
Full pressure testing should always be carried out hydraulically; because of the apparent
incompressibility of the hydraulic test fluid, any rupture which occurs causes immediate
loss of pressure without the explosive dissemination of shock waves and possibly debris
which would occur if gas was used.
Following the installation of wireline tools and make-up to the wellhead, the lubricator is
leak tested. A 50/50 freshwater/glycol mixture by volume is adequate for the testing of
lubricators only if mono-ethylene glycol is used, but a 60/40 freshwater/glycol mixture by
volume would be better.
The lubricator is normally pressure tested through the open Kill Wing Valve and up
through the Swab Valve which has been partially opened.

NOTE: Wellfluids must NEVER be used for pressure testing.

It is important that the number of turns required to fully open the swab valve hand wheel is
known, especially in gas wells where hydrates could form and prevent correct valve
operation. The number of turns should always be counted and recorded and the swab valve
is closed.
After a successful test, the pressure is bled back to anticipated CITHP plus 100-200 psi.
The swab valve is closed & the UMV is opened. The swab valve is then is opened slowly.
During pressure testing it must be realised that:
• Additional equipment will be required eg. a pump
• The fluid must be compatible with the well content if it is to be discharged into
the well on completion of the test; ie. a water and glycol mix.

 Expro North Sea Ltd. 1999 14.7

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NOTE: If water is used for pressure testing it should be realised that in a gas well
it could lead to hydrate formation, in an oil well it could form an
emulsion.

NOTE: If water is the only test fluid available, it must either be mixed with glycol
to prevent hydrate formation or be drained off after the test. It must not
be discharged into the well. Ensure that the line to the wellhead is
flushed with water/glycol mix prior to testing the lubricator.

• Diesel oil or condensate should not be used

• Care should also be taken to ensure that air is not introduced into the lubricator
through a leaking or partially immersed suction hose when filling the
lubricator. Equally, care should be taken to ensure that any trapped air is bled
off.

NOTE: Trapped air should not be present during any hydrostatic pressure test,
regardless of the fluid medium. Apart from the safety aspects,
satisfactory test interpretation becomes more difficult.

NOTE: Should there be a leak, direct high pressure fluid impingement on the
skin is extremely hazardous.

14.8  Expro North Sea Ltd.

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14.2.5 Pressure Testing Wireline BOPs
Blind Rams
The BOP rams are closed and pressure is applied from below by de-pressurising the
lubricator. Pressure is maintained for five minutes. Any pressure build up in the lubricator
may be observed on a gauge or fluid may be observed escaping through an open needle
valve fitted above the BOP.

Moulded Insert Rams or High Pressure Segment Type.

These can be tested on a live well by running the checking tool string below the BOP,
closing the BOP on the wire, de-pressurising the lubricator, and checking for leaks. On a
well with no pressure, the rams/segments should be closed on a piece of the appropriate
sized wire before the lubricator is stabbed. Pressure can then be introduced below the BOP
rams (eg. via a pump-in tee) again using a water/glycol mixture.

14.2.6 De-pressurising Lubricators

Following a wireline run, the lubricator will usually contain flammable and/or toxic gas
and therefore care must be taken when de-pressurising. The gas should be disposed of by
venting safely into the production process vent system or closed drain system. If this is not
possible and the gas has to be vented to atmosphere, care must be taken to ensure that there
are no personnel or ignition sources downwind. Whichever method is used and because of
the large volume of gas which may need to be discharged, venting must be a controlled
operation.

NOTE: Patience is a virtue in this case. De-pressurisation takes as long as it takes

and one should never attempt to accelerate the process.

NOTE: Equipment must be earthed to prevent ignition by static electricity.

 Expro North Sea Ltd. 1999 14.9

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14.10  Expro North Sea Ltd.

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15 APPENDICES

The following list refers to equipment fitted to the engine to achieve appropriate safety
standards:
• High capacity water cooled exhaust manifold
• Exhaust flame trap
• Exhaust spark arrestor
• Overspeed shutdown valve (automatic, fitted to inlet)
• Flame trap on inlet
• Seal crankcase
• Crankcase breather flame trap
• Sealed dip stick
• High temperature exhaust gas shutdown unit (200oC)
• High temperature coolant water shutdown unit (200oC)
• Low oil pressure shutdown
• Fuel shutdown vane or valve
• High capacity coolant radiator
• Non-metallic fan (radiator)
• Anti-static fan drive belts
• Engine oil cooler
• Air starters.

Electrically the units differ:

• EXD (FLP)- (110V) plugs and two lights on Arrow, D & W, and B15 units,
and 3 phase 440V stahl fire and gas detection systems on the A60s.

15.1.1 Safety Shutdown System

Under normal operating conditions, engine oil pressure is supplied to the following
equipment; see Figure 15.1:
• Overspeed valve
• Exhaust temperature valve
• Fuel shut off valve
• Control cylinder
• Water temperature valve.

If oil pressure is lost, or seriously reduced, the fuel shut off valve and air intake ‘D’ valve
closes, thus stopping the engine.

 Expro North Sea Ltd. 1999 15.1

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Figure 15.1 - Schematic of Safety Shutdown System

15.2  Expro North Sea Ltd.

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Oil pressure losses at the fuel shut off valve can be caused by any of the following:
1) Shortage of engine oil.
2) Damaged or broken oil line.
3) Oil pump failure.
4) High exhaust gas temperature causing valve to open, thus dumping oil.
5) High water temperature causing valve to open, thus dumping oil to sump.
6) Engine over-revving causing overspeed to dump oil to sump.

If the engine is overspeeding due to incorrect operator control or to flammable gas entering
the inlet manifold, in addition to f) above, the D valve will close off the inlet preventing
further entry of gas.

NOTE: Even if the fuel is shut off, the engine could continue to run on the
flammable gas entering the inlet manifold if the inlet manifold is not
closed off.

15.1.2 Exhaust Temperature Probes

Installation
The probe; see Figure 15.2, is installed in the 3/4 inch BSP socket in the manicooler exhaust
outlet adapter. Rotate it to the desired position and tighten the set screws. Do not use a
wrench on the aluminium valve body.
Pipe the pressure source to the “in” port; use a small amount of pipe sealant.
Operation
This is a normally closed valve, opening at 200oC (rising), suitable for use with oil/air
control systems with a restricted supply.

NOTE: That the maximum pressure at the “in” port is 125 psi.

Servicing
a) Hours (weekly); check tightness in pockets.
b) Hours (6 months); check settings and re-calibrate as necessary. Alternatively
replace with “Service Exchange Units”, (See Safesure Maintenance Scheme).

 Expro North Sea Ltd. 1999 15.3

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Figure 15.2 - Exhaust Temperature Probe

15.4  Expro North Sea Ltd.

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15.1.3 Coolant Temperature Probe
Installation
The probe; see Figure 15.3, is installed in a 1/2 inch BSP tapping in one of the thermostat
outlets. If there is not a suitable tapping available, one will have to be made as close as
possible to the thermostat bypass as possible. Before installing the probe, it is advisable to
run a 23/32 inch diameter tap drill through the lapping in which the unit will be placed. Some
commercial fittings are not tapped deep enough and the threads may damage the
temperature element cup.
Pipe the pressure source to the “in” port; use a small amount of pipe sealant.

Operation
This is a normally closed, two way valve opening at 100oC (rising) suitable for use with
oil/air control systems with a restricted supply.

NOTE: The maximum pressure at the “in” port is 125 psi.

Servicing
a) 50 hours (weekly); check tightness in pockets.
b) 1,000 hours (6 months); check settings and re-calibrate as necessary. Alternatively
replace with “Service Exchange Units” (See Safesure Maintenance Scheme).

Figure 15.3 - Coolant Temperature Probe

 Expro North Sea Ltd. 1999 15.5

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15.1.4 Engine Breather Flame Trap
Installation
Fit a new engine breather pipe with small flame trap element to valve cover; see Figure
15.4 Bracket pipe to engine. Make sure all joints are well sealed.

Maintenance
Inspect element every 6 monthly intervals.
To clean, wash in suitable solvent (e.g. petrol) and blow through with compressed air or HP
steam.

WARNING: NEVER ATTEMPT TO CLEAN BY INSERTING A PROBE

THROUGH THE PASSAGES AS THESE COULD BE ENLARGED
AND THE FLAME TRAP PERFORMANCE IMPAIRED.

Figure 15.4 - Engine Breather Flame Trap

15.6  Expro North Sea Ltd.

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15.1.5 Inlet System
The inlet system; see Figure 15.5, is comprised of the following:
a) Gasket: SVD-M Inlet Shutdown Valve.
b) Hex Head Bolt: M10 x 40 mm.
c) Plain Washer: M10.
d) Binx Nut: M10.
e) SVD-M Inlet Shutdown Valve (Oil Control).
f) Start/Reset/Emergency Stop Control Assembly.

NOTE: When assemblies with flanged connections are dismantled, gaskets must
always be renewed when re-assembling.

Figure 15.5- Inlet System

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15.1.6 D-Valve
This valve; see Figure 15.6, is an automatic inlet air shutdown valve (Pyroban) for
normally aspirated and turbocharged engines.
Installation
• Before installing the SVD-M inlet shutdown valve, ensure that any packing
material is blown clear.
• The SVD-M inlet shutdown valve must not be assembled upside-down.
• When pipework with flanged connections is dismantled, gaskets must always
be renewed when re-assembling.
• If an explosion occurs in service, the SVD-M inlet shutdown valve must be
exchanged for a new component or re-tested.
• Fit with the inlet flametrap element on the engine side of the SVD-M inlet
shutdown valve.

Fit the SVD-M inlet shutdown valve as close as possible to the engine. The further the
flametrap element is from the engine, the less effective it is. Actual flame arresting
performance can only be determined by means of a flame test in an arrangement accurately
representing the final installation.
The entire inlet system between the SVD-M inlet shutdown valve and the engine must
withstand 10 bar pressure.
All other air inlets between the SVD-M inlet shutdown valve and the engine must be closed
or re-routed to prevent ingress of air or other gases after shutdown.
An efficient dry type air filter must be fitted upstream of the SVD-M inlet shutdown valve.
Regular attention to the air filter together with fitting of a service indicator will prevent
fouling of the integral flametrap and subsequent attention; see maintenance information.
Attach the operating cable to the stop/reset lever with the lever in line with the SVD-M
inlet shutdown valve axis. The cable operating lever can be located in any convenient
position subject to a minimum bend radius of 150 mm. The label (start/stop/emergency
stop) mounted alongside the lever must be compatible in the direction of movement. The
operating head is reversible on the cable end by slacking the two set screws on the head
and is recommended that, where possible, the lever is pulled towards the operator for
“emergency stop”.
The cable should move sufficiently to open the SVD-M inlet shutdown valve and enable it
to latch. Check that with the cable in the neutral position, the control arm is free to go to
the closed (overspeed) position.
After positioning the cable operating head, check that the cable inner is not subjected to
any twisting. If necessary, release and re-tighten the locknut securing ball joint at the SVD-
M inlet shutdown valve end of the cable inner.
The valve operating gear is manufactured from stainless steel and must not be painted.

15.8  Expro North Sea Ltd.

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Figure 15.6 - SVD-M Inlet Shutdown Valve With Oil Control

 Expro North Sea Ltd. 1999 15.9

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Operation
The start/reset/emergency stop control and cable mechanism allows the SVD-M inlet
shutdown valve to be ‘A’ held open to start the engine or ‘B’ closed for emergency stop.
The control cylinder is retained in the open position with an oil separator plunger. The
plunger holds the trip lever until lack of oil pressure allows its release. The trip lever also
allows the SVD-M inlet shutdown valve to close with the plunger up - this is the
“overspeed condition”. To reset the SVD-M inlet shutdown valve, push and hold the
start/reset/emergency stop control in the “reset” position until maximum oil pressure is
achieved, then return the control to the neutral position.

NOTE: It may not be possible to reset the SVD-M inlet shutdown valve until
approximately 30 seconds after engine vacuum. Do not try and reset the
SVD-M inlet shutdown valve mechanism against this vacuum.

Maintenance
At 100 hours (or 2 weeks) inspect the control mechanism and ensure the roller on the trip
lever is free to spin. Lubricate the valve spindle and all pivot points with thin oil. Carry out
an emergency stop test by selecting “Emergency Stop” with the start/reset/emergency stop
control. Ensure that the control mechanism moves freely, closes correctly and shuts the
engine. If operation of the SVD-M inlet shutdown valve appears to be satisfactory but the
engine does not stop within a few seconds then the inlet system including the inlet
manifold should be checked for leaks.
At 500 hours (or 3 months) recheck the overspeed setting.

Setting the SVD-M Inlet Shutdown Valve

Assemble the complete inlet system from the engine to air filter before attempting to set the
SVD-M inlet shutdown valve overspeed spring. This is very important - an accurate setting
cannot otherwise be achieved.
Fully warm up the engine (some initial adjustment of the SVD-M inlet shutdown valve
may be necessary to enable the engine to run at a suitable speed).
Use the control arm to reset the SVD-M inlet shutdown valve. It may not be possible to
reset the SVD-M inlet shutdown valve until approximately 30 seconds after a shutdown
due to the high engine inlet system vacuum.

NOTE: Do not attempt to reset the SVD-M inlet shutdown valve against this
vacuum

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When fully warmed up, adjust the overspeed spring as follows:
a) If the existing setting gives shutdown below engine high idle (ie. max throttle/min
load) turn the adjuster screw one turn clockwise and recheck. Continue this with
finer adjustments if necessary until the SVD-M inlet shutdown valve gives a
shutdown at or just below high idle. If the existing setting does not give shutdown,
turn the adjuster screw two or more turns anticlockwise as necessary to give
shutdown below high idle and then adjust as above.
b) After completing a), turn the adjuster screw one full turn clockwise.
c) Rapidly accelerate the engine up to high idle three or four times. If there is any
tendency for the SVD-M inlet shutdown valve to actuate, repeat operations a) and
b) above.
d) Tighten the locknut and wire-lock (always use new stainless steel wire).
e) Check the emergency stop by operating with the engine running.
The overspeed setting operation should be checked after the first 100 hours (or 2 weeks,
whichever is sooner) to allow for bedding in, and thereafter at 500 hours (or 3 months,
whichever is sooner) intervals.

Figure 15.7 - Control Mechanism

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15.1.7 CLEANING THE INLET FLAMETRAP ELEMENT
Provided the maintenance and servicing of the induction air filter is carried out regularly,
the inlet flametrap need not be cleaned. If the engine performance is affected due to a
partially blocked inlet flametrap, the inlet flametrap can be washed in petrol or suitable
solvent, then blown through with compressed air. Do not attempt to remove the flametrap
element from the by SVD-M inlet shutdown valve. Do not clean the flametrap by inserting
probes as the fine passages could be enlarged thereby impairing the flametrap performance.
After cleaning, lubricate the SVD-M inlet shutdown valve spindle, operating arm and pivot
points/bushes in addition to re-lubricating the external parts as mentioned above.

15.1.8 ADDITIONAL SAFETY NOTES

The SVD-M inlet shutdown valve is a critical part of the safety system. It is vital that the
servicing requirements are strictly carried out. If there are any doubts about the proper
operation of the SVD-M inlet shutdown valve it is strongly recommended that either a
Pyroban Service Engineer is requested to service the SVD-M inlet shutdown valve or
alternatively a Service Exchange Unit be obtained from Pyroban and fitted. In any case, it
is recommended that during major overhauls of the equipment protected by the SVD-M
inlet shutdown valve a “Service Exchange Unit” be fitted.
The SVD-M inlet shutdown valve operating mechanism must not be interfered with in any
manner that could cause the valve to remain open.
When pipework with flanged connections is dismantled, gaskets must always be renewed
when re-assembling.
If an explosion occurs in service, the SVD-M inlet shutdown valve must be exchanged for
a new component or re-tested.

15.12  Expro North Sea Ltd.

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15.1.9 EXHAUST SYSTEM
Typical Manicooler Arrangement
The manicooler is comprised of the following items:
a) Exhaust Outlet Box
b) Fixing Kit: Exhaust Flametrap/Outlet Box
c) Gasket: Manicooler/Access Door
d) Gasket: Cylinder Head/Adapter Plate
e) Adapter Plate
f) Socket cap Screw: M10 x 25 mm
g) Gasket: Adapter Plate/Manicooler
h) Stud: M10 x 46 mm x M10
i) Plain Washer: M10
j) Nut: M10
k) Manicooler
l) Exhaust Flametrap (Plate Type)
m) Dummy Exhaust Flametrap
See Figure 15.8.
Ensure that suitable plugs are fitted in all unused sockets on the manicooler, access door
and exhaust outlet box.
When pipework with flanged connections is dismantled, gaskets must always be renewed
when re-assembling.

NOTE: The safety officer must be consulted before fitting a dummy exhaust
flametrap to the system.

 Expro North Sea Ltd. 1999 15.13

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Figure 15.8 - Typical Manicooler Arrangement

15.14  Expro North Sea Ltd.

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15.1.10 TROUBLESHOOTING - DIESEL ENGINES
Think Before Acting
Study the problem thoroughly. Ask these questions:
1) What were the warning signs preceding the trouble?
2) What previous repair and maintenance work has been done?
3) Has similar trouble occurred before?
4) If the engine still runs, is it safe to continue running it to make further checks?

Do Easiest Things First

Most troubles are simple and easily corrected, examples are “low power” complaints
caused by loose throttle linkage or dirty fuel filters, “excessive lubricating oil
consumption” caused by leaking gaskets or connections etc.
Always check the easiest and obvious things first; following this simple rule will save time
and trouble.

Double Check Before Beginning Disassembly Operations

The source of most engine troubles can be traced not to one part alone but to the
relationship of one part with another. For instance, excessive fuel consumption may not be
due to an incorrectly adjusted fuel pump, but instead, to a clogged air cleaner or possibly a
restricted exhaust passage, causing excessive back pressure. Too often, engines are
completely disassembled operations. Check again to be sure an easy solution to the
problem has not been overlooked.

Find And Correct Basic Cause Of Trouble

After a mechanical failure has been corrected, be sure to locate and correct the cause of the
trouble so the same failure will not be repeated. A complaint of “sticking injector
plungers” is corrected by replacing the faulty injectors, but something caused the plungers
to stick. The cause is may be improper injector adjustment, or more often, water in the
fuel.
If the engine will not start, the following is a list of investigative checks:
1) Check stop control operation/run position.
2) Check fuel level shutdown valve is in the reset/start position.
3) Check fuel tank level.
4) Check fuel tank supply valve is open.
5) Check D-valve control mechanism is in the open start position.

 Expro North Sea Ltd. 1999 15.15

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a) Engine Will Not Start
• Starter Trouble. (Check air start supply).
• Compression Poor (Check Valves and Rings)
• Valve Timing Incorrect (Re-Time)
• Air Throttle not Opening (Check Linkage)
• Water or Air in Fuel
• Stop Control Stuck

A diesel engine, in order to operate, requires only a properly timed fuel charge being
sprayed through an injector into a cylinder of sufficiently compressed hot air to ignite the
fuel charge. The air supply system and the exhaust system must also be timed and
unrestricted.
If the engine does not turn when the starter is energised, check the starter current draw; if
the reading is high, repair the starter, if the reading is low or zero, check the starter switch
and switch-to-starter cable. If an air starter is fitted, check the air supply pressure is high
enough; if it is, the starter will have to be replaced or repaired.
When the engine turns and will not start, remove one or more injector lines at the injector
and check for fuel during cranking. If no fuel flow is evident, check fuel valves, filters, lift
pump, lines and fuel supply. There may be sufficient fuel supply, but good compression is
also necessary. Do not forget the primer injection pump.

b) Fuel System
1) Bleed all air from the fuel system. If the air cannot be eliminated, check the fuel line
to the pump from the fuel tank. Ensure all connections are tight.
2) Push the excess fuel button and check the control rod moves freely to the "excess-
fuel" position.
3) Disconnect the injector lines at the injector and turn the engine with the starter. The
fuel delivery from each line should be approximately equal.
4) With the lines disconnected, pull the stop control and operate the lift pump hand
primer. Any flow of fuel indicates a faulty delivery valve or a broken delivery valve
spring.

Connect the lines and start the engine. As a rough check for injector conditions, operate the
engine just above the idling speed and loosen the injector lines one at a time. As each
injector is "cut out", a definite drop-off in speed should be noticed if the injector is
operating correctly.

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c) Air Supply
1) Be sure that the air cleaner is not obstructed and that all air passages are open.
2) Check to make sure there are no obstructions between the main air cleaner and the
intake manifold. Operate the pneumatic governor control, if so equipped and make
sure that the throttle plate travels as far as its stop, giving sufficient opening at the
throttle.

CAUTION: MAKE SURE THAT NO FLAMMABLE GASES CAN GET TO AIR

INTAKE AS THE ENGINE WILL RUN ON THESE GASES AND
CAN BE SERIOUSLY DAMAGED.

d) Engine Lacks Power

• Poor Compression (Check Valves and Rings)
• Injection Timing Incorrect (Re-time)
• Stop Control Stuck Out (Release)
• Throttle Movement Restricted (Adjust)
• Air Cleaner Dirty (Clean)
• Governor Spring Weak (Renew)
• Engine Overheating. (Check coolant, thermostat, radiator, fan belts).

When the engine lacks power and the trouble is traced to the fuel system (by eliminating
mechanical possibilities such as compression, throttle linkage, air cleaner restriction, etc.),
then the trouble is one of the following: not enough fuel, too much fuel, poorly timed
injection, or improperly functioning injectors.
Insufficient fuel is due to dirt, blocked filters, restricted lines, bad lift pump, maladjusted
control rod or plunger fork, or air in the low pressure portion of the fuel system.
Too much fuel in any individual cylinder is usually the result of the plunger operating
fork(s) being out of adjustment. If a generally rich condition is noticed in all cylinders, look
for a sticking excess fuel device.
Carboned or damaged injectors can give the indication of too much or not enough fuel.
Injectors should be cleaned and checked according to the maintenance schedule.
Low engine power can stem from either fuel or mechanical problems. Check the most
obvious items first. Be sure that the throttle linkage is moving the injection pump control
rod through its full travel. Bar the engine over until the 19 or 20 degrees (depending on the
engine) mark on the flywheel is aligned with the notch on the housing. The timing marks
on the pump coupling and the pump should be aligned. Check the lift pump.
Some other situations that can cause a real or indicated loss of power are: overheating, dirty
air cleaner, overloaded engine, wrong fuel or restricted exhaust system.

 Expro North Sea Ltd. 1999 15.17

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e) Engine Runs Rough
• No Fuel at Injector(s)
• Low Cylinder Compression
• Carboned or Damaged Injectors
• Plugged Fuel Filters
• Low Primary Fuel Pump Pressure
• Poor, Contaminated Fuel or Water in Fuel
• Incorrect Valve Timing
• Wrong Injection Pump Timing

The trouble symptom, "Engine Lacks Power", is very closely related to a rough-running
engine. Therefore, it is suggested that the possibilities mentioned under "Engine Lacks
Power" be checked first.
Again, the most likely items should be checked first. Roughness is caused by unequal
power impulses from each cylinder. To determine which cylinder(s) is at fault, loosen each
injector tube at the injector, one at a time, with the engine running and note which cut-out
cylinder(s) makes a difference in running. Then check for fuel and/or compression on that
cylinder. Check the injector while it is out, for compression.
If the engine "miss" is not confined to any particular cylinder(s), look for carboned
injectors, poor or watered fuel, air in the fuel system, improper injection pump or intake
and exhaust valve timing, worn or damaged engine or transmission mounts.

f) Engine Emits Excessive Smoke

Determining the conditions under which the engine smokes and the colour of the smoke
can save considerable time in correcting the problem.
Blue smoke during acceleration is usually an indication of worn piston rings. In the early
stages of ring wear, blue smoke when accelerating after deceleration is similar to a worn
valve guide indication. The exact source of blue smoke can be found by a compression test
and valve stem and guide clearance check.
Black smoke is the result of partially burned fuel. This can be either too much fuel or
incomplete burning of the normal fuel charge. Usually the black smoke is from one of three
causes: full-throttle fuel setting at low engine speed, retarded injection timing, or carboned
injection nozzles. An excessively low octane number fuel can also cause black smoke.
A white smoking condition indicates vaporised fuel that has not been burned, low cylinder
compression, extremely late injection timing or water leaking into the cylinder.

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g) Engine Starts and Stops
• Water or Air in Fuel
• Restricted Fuel Line
• Weak Primary Fuel Pump
• Fuel Tank Vent Plugged
• Pump Control Rod Stuck in Shut Position

Intermittent engine operation usually means that a small amount of fuel is reaching the
cylinders, but not in sufficient quantity to allow continuous operation.
Air in the fuel system is a common source of this trouble. The air will most likely be found
between the injection pump and the tank. Any in the system, between the injection pump
and the injector, will be forced through the injector by high-pressure fuel.
Another logical place to look for fuel restriction is in either of the filters. Both should be
checked according to the engine maintenance schedule.
A weak fuel pump will sometimes supply enough fuel to start an engine, but not enough to
keep it running. Check the lift or low-pressure pump with a vacuum gauge on the pump
inlet and a pressure gauge on the pump outlet. If the vacuum and pressure are within
specifications, measure the volume of fuel delivered over a period of time. Compare the
results of the above tests with specifications.
If no gauges are available, a weak lift pump can usually be detected by disconnecting the
line to injector pump and turning the engine over the starter. If the pump is weak, fuel will
surge radically rather than be pumped in steady surges.
In the event no trouble is found during the above tests, look for water or poor fuel in the
system. A restriction in the fuel tank lines should not be overlooked.
A starting and stopping engine is usually the result of an intermittent fuel supply which
includes water and/or air in the fuel.
A restricted fuel line or weak lift pump will cause the above condition. The fuel tank cap
must be vented. If a rush of air is noted, when the cap is removed, the vent is plugged.
Since the control rod in the injection pump is connected to the governor through a spring or
diaphragm, it is possible for the control rod to stick in any position including the shut-off
position.

 Expro North Sea Ltd. 1999 15.19

Wireline Module 1
h) Bleeding the Fuel System
The following procedure must be followed in bleeding the system to make certain that all
air has been expelled that could cause misfiring or erratic operation.
1) Make sure that there is fuel in the tank and that the fuel line valve(s) is open.
2) Open the bleed valve on the inlet side of the secondary fuel filter. Operate the lift
pump priming lever until the fuel that flows from the inlet bleed valve is free of air
bubbles. Be sure to close the bleed valves with the priming lever on the downstroke.
3) Close the inlet bleed valve and open the outlet bleed valve. Operate the lift pump
priming level until fuel flows from the outlet bleed valve free of air bubbles.
4) Close the outlet bleed valve, open the bleed valve(s) on the injection pump gallery
and expel all the air.
5) Close the injection pump gallery bleed valve(s) and wipe all surplus fuel from the
injection pump and secondary fuel filter body.

i) Fuel Lift Pump Filter Screen

To clean the fuel pump filter screen, unscrew the centre bolt and lift off the cover and
screen. Wash the screen with solvent, then install the screen. Fit a new gasket to the top
cover and install it. Do not overtighten the centre bolt.
Bleed the air from the fuel system.

j) Testing the Fuel Lift Pump

Providing there are no air leaks or obstructions in the fuel system, a quick check on the
pump efficiency can be made as follows:
1) Remove the air bleed screw from the inlet side of the fuel filter that is on the pressure
side of the fuel lift pump.
2) Operate the hand-priming lever in the normal manner. There should be a well defined
surge of fuel for each working stroke of the pump. If there is no resistance of the
diaphragm spring, it is likely that the diaphragm is held down. This is due to the
operating lever being on the high point of the eccentric. It will be necessary to rotate
the engine approximately one turn.
If the pump does not operate correctly, check the vacuum and delivery pressure with a
suitable vacuum and pressure gauge.

15.20  Expro North Sea Ltd.